Stirred Tank Fermentor Research Articles

Oxygen transfer rate in stirred-tank fermentors under the supply of oxygen-enriched air

The oxygen transfer rate (OTR) in 0.2-m 3 and 2-m 3 stirred-tank fermentors having two sets of standard six-blade turbine impellers was determined by the sulfite oxidation method under the supply of oxygen-enriched air. Since the observed OTR values did not correlate very well with the ones calculated using the known empirical equations, a new empirical equation was derived by the least squares method.

Pilot-scale ethanol fermentation by Zymomonas mobilis from simultaneously saccharified sago starch

Abstract A simultaneous saccharification of sago starch and ethanol fermentation (SSF), by an enzyme, amyloglucosidase, and a bacterium, Zymomonas mobilis, was studied at pilot-scale. Various SSF processes were performed in batch and semi-batch modes. In the batch SSF processes using a 72 litre stirred-tank fermentor, the final ethanol concentration obtained from 20% (w/w) sago starch was 92·6 g litre−1 with 97·4% of the theoretical ethanol yield. In 100 and 500 litre airlift fermentors equipped with systems for self-mixing by CO2 recycle the fermentation kinetics were similar to those obtained from the stirred-tank fermentor. Semi-batch SSF processes using a cell-recycle system by ultrafiltration gave about 80% increase of ethanol productivity compared with batch SSF processes.

Kinetics of Peroxidase Production by Streptomyces viridosporus and Recombinant Streptomyces lividans

AbstractThe production of peroxidases by Streptomyces viridosporus T7A and recombinant Streptomyces lividans TK64.1 was characterized in stirred tank fermentors. The rate of peroxidase production was strongly growth associated with plasmid‐coded S. lividans, in contrast to chromosome‐coded S. viridosporus, where peroxidase production was proportional to cell mass rather than cell growth rate. A modified form of the logistic equation gave a good fit to the experimenal data for cell growth and peroxidase formation.

Gas holdup, power consumption, and oxygen absorption coefficient in a stirred‐tank fermentor under foam control

For a laboratory stirred-tank fermentor (STF) with foaming system of 0.5M sulfite solution containing an anionic soft detergent, the performing of a foam-breaking apparatus with a rotating disk (FARD)fitted to the STF was evaluated. The gas holdup in a mechanical foam-control system (MFS), i.e., the stirred-tank fermentor with the rotating disk foambreaker, was confirmed to be larger than that in a nonfoaming system (NS), i.e., the STF with an antifoam agent added. The agitation power in the mechanical foam control system was found to be smaller compared with the agitation power in the nonfoaming system, due to the increased gas holdup. Comparison of the oxygen absorption coefficient between the mechanical foam control system and the nonfoaming system in terms of the specific power input also demonstrated the superiority of the mechanical foam control system, not only in oxygen transfer performance but also in power input economy.

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.

Mechanisms for biopolymer accumulation in immobilized Acinetobacter calcoaceticus system

The gram-positive bacteria, Acinetobacter calcoaceticus, is capable of accumulating biopolymer in the carrier matrix of an immobilized cell system. Several possible mechanisms for the biopolymer accumulation are evaluated. It appears that direct solid surface polymer adsorption and polymer diffusion limitation within the pore space are minor factors in biopolymer accumulation. Calculations demonstrate that the cell bound polymer to dry cell weight ratio is much higher for immobilized cells than for free cells. The higher cell-bound polymer to dry-cell-weight ratio for immobilized cells as well as the accumulation of the immobilized cells in the Celite matrix are believed to be the main factors for biopolymer accumulation in the Carrier matrix. Further studies reveal that the cell-bound polymer to dry-cell-weight ratio is strongly affected by shear forces. At zero shear stress, such as would be present in the carrier matrix, cell bound polymer to dry cell weight ratio can be as high as 1.6. As the shear stress increases, this ratio decreases. When shear stress increases above 5 dyn/cm(2), a level equivalent to the shear experienced by free cells in a stirred tank fermentation, cell-bound polymer decreases to less than 20% of dry cell weight. A macroscopic model is developed to describe the effect of shear stress on the cell-bound polymer to dry-cell-weight ratio.

Xanthan batch fermentations: compared performances of a bubble column and a stirred tank fermentor

Fermentations of Xanthomonas campestris, NRRL B-1459, were carried out in a bubble column fermentor (BCF) and in a stirred tank fermentor (STF) to allow comparison of representative variables measured during the microbial growth and the gum production.

Increased oxygen transfer in a yeast fermentation using a microbubble dispersion

A microbubble dispersion (MBD) was used to supply oxygen for aerobic fermentations in a standard 2 L stirred tank fermenter. The microbubble dispersion was formed using only surfactants produced naturally. Growth rates ofSaccharomyces cerevisiae cultures were found to be equal or greater with MBD sparging than with gas sparging. The oxygen transfer coefficent with MBD sparging was found to be 190/h and independent of impeller speed from 100–580 rpm. The oxygen transfer coefficient with air sparging rose from 55 to 132/h over the same range of impeller speeds. Power requirements for the fermenter systems were estimated.

Denaturation/Refolding of Purified Recombinant HIV Reverse Transcriptase Yields Monomeric Enzyme with High Enzymatic Activity

We engineered a prokaryotic expression vector encoding the HIV reverse transcriptase (RT). We grew Escherichia coli JM109 carrying the vector in a 250-liter stirred tank fermentor and purified RT (p66) under native conditions to apparent homogeneity. Purified p66 (greater than or equal to 5 mg/ml) was not stable, and was rapidly processed to its 51 kD derivative (p51), until p66:p51 levels were approximately 1:1. These latter RT preparations were chromatographed as heterodimers and had approximately fivefold higher specific RT enzymatic activities compared with those containing predominantly p66. P66 purified under dilute concentrations (less than or equal to 0.5 mg/ml) was monomeric in solution, resistant to p51 processing for weeks at 4 degrees C, but also had low specific RT enzymatic activities. To attempt the preparation of homogeneous p66 with specific RT enzymatic activities equivalent to p66:p51 heterodimers, purified heterodimers were denatured and p66 was purified and refolded during extensive dialysis (refolded p66). Refolded p66 (less than or equal to 0.5 mg/ml) was monomeric in solution and had identical specific RT enzymatic activities, Km for dTTP, and inhibition by 3'-azido-3'-deoxythymidine triphosphate compared with heterodimeric p66:p51 RT. The data indicates that HIV RT obtained from recombinant E. coli under native conditions is extensively processed at concentrations promoting dimerization. Moreover, RT denaturation and refolding yields apparently homogeneous monomeric p66, with specific RT enzymatic activities equivalent to heterodimeric RT.

Spin Filter Perfusion System for High Density Cell Culture: Production of Recombinant Urinary Type Plasminogen Activator in CHO Cells

We have used a 20 liter stirred tank fermentor, equipped with a 127 mesh ethylene-tetrafluoroethylene rotating screen for cell recycle, for the continuous production of recombinant single chain urokinase-type plasminogen activator (rscu-PA) from Chinese hamster ovary (CHO) cells. Viable cell densities between 60 and 74 million per ml were maintained at medium perfusion rates of 3.0 to 4.0 fermentor volumes per day. Cells were retained by the 120 micron nominal opening filter through the formation of "clumped" cell aggregates of 200 to 600 microns in size, which did not foul the filter. In 31 days of culture, a total of 51 grams of rscu-PA were produced in 1,000 liters of medium. The rscu-PA produced over the course of this continuous culture was purified and characterized both in vitro and in vivo and shown to be comparable to natural scu-PA produced from the transformed human kidney cell line, TCL-598.

Large-scale preparation of recombinant platelet-derived growth factor AA secreted from recombinant baby hamster kidney cells.

The short isoform of platelet-derived growth factor A (PDGF-A) was expressed in a mammalian host (BHK-21 cell). A cell line was obtained that secreted up to 0.3 micrograms/10(6) cells recombinant PDGF-A chain homodimer/day into the medium. For large-scale production of supernatant, cells were grown either in roller bottles or in 2.5-1 stirred tank fermenters. A simple two-step procedure was developed to purify recombinant PDGF-AA (rPDGF-AA). The first step was adsorption onto porous glass and the final step was reversed-phase high-performance liquid chromatography. The yield was 0.2 mg/l supernatant. A total amount of 20-30 mg pure rPDGF-AA may be obtained from a single fermenter run. Sequence analysis showed the correct amino terminus and no internal proteolytic cleavages. The specific activity was 5 ng/ml for mouse AKR-2B cells. [125I]rPDGF-AA had an affinity constant of approximately 0.5 nM to these cells and 25,000 binding sites were estimated/cell.

Kinetics of whey–lactose acidogenesis

The mixed-culture anaerobic conversion of lactose to organic acids in a bench-scale continuous-flow stirredtank fermentor is considered. The major acidogenic end-product distribution with respect to the dilution rate are presented. A Monod chemostat model is employed to describe a microbial growth, and the influence on pH of the estimated model parameters is discussed.

Sparger position effect over kLa in bench and pilot stirred-tank fermentors

The present investigation describes the influence of sparger position in relation to the volumetric oxygen transfer coefficient of the liquid film ( k L a) in tanks of four different sizes. It was found that the influence of the sparger position on ( k L a) is more evident as the scale increases.

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.

Low‐pressure airlift fermenter for single cell protein production: I. Design and oxygen transfer studies

The energy consumption of a fermenter constitutes a major part of the operating expense of a single cell protein process. A low-pressure airlift fermenter was designed to reduce this cost. In this new design, the fermenter broth is kept below 120 cm in depth, and air alone is employed to fulfill the need of supplying oxygen, and cooling and agitating the broth. The use of low-pressure air from air blowers instead of air compressors lowers the capital cost of air delivery and reduces the energy consumption in the fermenter section to below 1 kWh/kg protein, a saving of over 70% as compared to a conventional stirred tank fermenter. It also eliminates the investment of mechanical agitators, heat exchangers, and air compressors. Sulfite oxidation studies confirmed the design concepts.

Copper uptake in Aspergillus niger during batch growth and in nongrowing mycelial suspensions

Copper accumulation by the filamentous fungus Aspergillus niger from a glucose mineral salts medium containing copper in the concentration range 16 to 157 μ M was maximal in the lag phase of growth. In the subsequent linear growth phase, the mycelial copper contents were dramatically reduced on a per gram dry weight basis. The fungal mycelium exhibited pelleted morphology and exponential growth was not apparent. The medium pH was reduced during growth in flask cultures, but this was not responsible for the reduction in copper uptake as indicated by the similar effect in cultures grown in a stirred-tank fermenter with electronic maintenance of pH at 5.5. Voltammetric analysis of medium which had supported growth of the fungus showed that copper added at a final concentration of 40 μ M was complexed. Energy-dependent copper uptake from 2-( N-morpholino)ethanesulfonic acid buffer at pH 5.5 containing 40 μ M copper could not be demonstrated in nongrowing mycelium. Incubation at 4°C reduced copper uptake while the presence of 10 m M glucose or preincubation of the mycelium in 1 m M sodium azide had no effect on copper uptake.

Growth kinetics of Dioscorea deltoidea and Catharanthus roseus in batch culture

Sugar-limited batch growth of Dioscorea deltoidea and Catharanthus roseus plant cell cultures was studied in a 14-L stirred tank fermentor. With dissolved oxygen concentration monitored and maintained at nonlimiting levels, growth rates and ratios of dry weight to fresh weight were found to be strongly influenced by sugar concentration. Linear relationships between respiration rate and growth rate were observed, and respiration rate was found to drop to a maintenance level after sugar had been fully depleted from the medium. Diosgenin biosynthesis by D. deltoidea was shown to be independent of growth rate. Ajmalicine biosynthesis in C. roseus was negligible during sugar-limited growth but was induced by inoculation into an 80-g/L glucose solution.