Performance analysis of an immobilized yeast packed-bed reactor for ethanol fermentation

The performance of an immobilized packed-bed bioreactor for continuous ethanol fermentation was evaluated. Immobilized yeasts were prepared by entrapment in calcium alginate gel. An axial dispersed plug flow model incorporating the effects of substrate and product inhibition on fermentation kinetics was developed. The model equations were solved by the method of orthogonal collocation and the suitability of the reactor model to predict the conversions obtained in this biocatalytic reaction system was assessed.     

Continuous ethanol fermentation using immobilized yeast in a fluidized bed reactor

Continuous ethanol fermentation of glucose using fluidized bed technology was studied. Saccharomyces cerevisiae were immobilized and retained on porous microcarriers. Over two-thirds of the total reactor yeast cell mass was immobilized. Ethanol productivity was examined as dilution rate was varied, keeping all other experimental parameters constant. Ethanol yield remained high at an average of 0.36 g ethanol g^?1 glucose (71% of theoretical yield) as the dilution rate was increased stepwise from 0.04 h^?1 to 0.14 h^?1. At a dilution rate of 0.15 h^?1, the ethanol yield steeply declined to 0.22 g ethanol g^?1 glucose (44% of theoretical yield). The low maximum percentage of theoretical yield is primarily due to an extended mean cell residence time, and possibly due to the inhibitory effect of a high dissolved carbon dioxide concentration, enhanced by the probable intermittent levels of low pH in the reactor. Constant ethanol production was possible at a high glucose loading rate of 840 g dm^?3 day^?1 (attained at a dilution rate of 0.14 h^?1). Although the highest average ethanol concentration (97.14 g dm^?3) occurred at the initial dilution rate of 0.04 h^?1, the peak average ethanol production rate (2.87 g (g yeast)^?1 day^?1) was reached at a greater dilution rate of 0.11 ^h-1. Thus, the optimal dilution rate was determined to be between 0.11 h^?1 and 0.14 h^?1. Ethanol inhibition on yeast cells was absent in the reactor at average bulk-liquid ethanol concentrations as high as 97.14 g dm^?3. In addition, zero-order kinetics on ethanol production and glucose utilization was evident.     

Experimental, kinetic and 2-D reactor modeling for simulation of the production of hydrogen by the catalytic reforming of concentrated crude ethanol (CRCCE) over a Ni-based commercial catalyst in a packed-bed tubular reactor

Mechanistic kinetic models were formulated based on Langmuir-Hinshelwood-Hougen-Watson and Eley-Rideal approaches to describe the kinetics of hydrogen production by the catalytic reforming of concentrated crude ethanol over a Ni-based commercial catalyst at atmospheric pressure, temperature range of 673-863 K, ratio of weight of catalyst to the molar rate of crude ethanol 3472-34722 kg cat s/kmol crude in a stainless steel packed bed tubular microreactor. One of the models yielded an excellent degree of correlation, and was selected for the simulation of the reforming process which used a pseudo-homogeneous numerical model consisting of coupled material and energy balance equations with reaction. The model was solved using finite elements method without neglecting the axial dispersion term. The crude ethanol conversion predicted by the model was in good agreement with the experimental data (AAD%=4.28). Also, the predicted concentration and temperature profiles for the process in the radial direction indicate that the assumption of plug flow isothermal behavior is justified within certain reactor configurations. However, the axial dispersion term still contributed to the results, and thus, cannot be neglected.     

Continuous ethanol production from carob pod extract by immobilized Saccharomyces cerevisiae in a packed-bed reactor

The continuous production of ethanol from carob pod extract by immobilized Saccharomyces cerevisiae in a packed-bed reactor has been investigated. At a substrate concentration of 150 g dm^?3, maximum ethanol productivity of 16 g dm^?3 h^?1 was obtained at D = 0·4 h^?1 with 62·3% of theoretical yield and 83·6% sugars′ utilization. At a dilution rate of 0·1 h^?1, optimal ethanol productivity was achieved in the pH range 3·5–5·5, temperature range 30–35·C and initial sugar concentration of 200 g dm^?3. Maximum ethanol productivity of 24·5 g dm^?3 h^?1 was obtained at D = 0·5 h^?1 with 58·8% of theoretical yield and 85% sugars′ utilization when non-sterilized carob pod extract containing 200 g dm^?3 total sugars was used as feed material. The bioreactor system was operated at a constant dilution rate of 0·5 h^?1 for 30 days without loss of the original immobilized yeast activity. In this case, the average ethanol productivity, ethanol yield (% of theoretical) and sugars′ utilization were 25 g dm^?3 h^?1, 58·8% and 85·5%, respectively.     

Optimal feed temperature for an immobilized enzyme packed-bed reactor

Optimal feed temperature was determined for a nonisothermal immobilized enzymatic reaction with enzyme deactivation in a packed-bed reactor. The optimal feed temperature was obtained by maximizing the average substrate conversion over a given reaction period. Simulation showed the optimal feed temperature to be strongly dependent on the flow dispersion, the reaction activation energy, the corresponding enzyme inactivation energy and the heat of reaction. It was also observed that in a plug flow reactor the enzyme reaction generally exhibited a lower optimal feed temperature and higher substrate conversion than in a continuously stirred tank reactor.     

Characterization of Saccharomyces cerevisiae immobilized onto chrysotile for ethanol production

Saccharomyces cerevisiae (CCT 3174 and commercial baker's yeast) was immobilized by adsorption onto chrysotile. The adsorbed yeast cells were easily washed out, but cells grown in situ were strongly attached by entrapment by chrysotile microfibres. In fermentation experiments with 30% (w/v) glucose solution, the immobilized cells showed a 1·3-fold increase in initial reaction velocity. For immobilized CCT 3174, the final ethanol yield was 26% higher than that with free cells. © 1998 Society of Chemical Industry     

乙醇发酵反应器的研究进展

主要介绍了气升式反应器、固定化细胞反应器及膜生物反应器在乙醇发酵生产酒精的应用,讨论了各反应器的优缺点,探讨了其工业化应用的可能性,最后分析了各反应器设计的发展方向。     

Alcoholic fermentation by immobilised yeast cells

Ethanol production by yeast cells immobilised in carrageenan gel beads and operated in a continuous tubular reactor reached 15 g dm^?3 h^?1 with a glucose feed of 165 g dm^?3; a glucose residence period of 4.6 h was noted. The minimal cell loading to obtain uniform particles was 10⁴ colony-forming units per g of gel, although particles achieved a content of 10⁸ CFU g^?1 independent of the initial cell concentration. Scanning electron and phase contrast microscopy confirmed that growth inside the gel beads was probably limited by substrate diffusion through the denser outer layer observed.     

环流反应器中固定化酵母乙醇连续发酵研究

制备了一种重化固定化酵母颗粒，可有效防止发酵过程中固定化颗粒上浮，用于气升式内环流反应器，可与器内流体形成良好循环。同时在气升式内环流反应器内对固定化酵母乙醇连续发酵过程进行了研究，得到发酵最优控制条件。通过与其它发酵器对比发现，内环流反应器用于固定化酵母乙醇发酵过程，可大大提高乙醇产率。     

Yeast fermentation in a cocurrent downflow contacting reactor (CDCR)

The growth kinetics and mass transfer characteristics of Saccharomyces cerevisiae in a cocurrent downflow contacting reactor (CDCR) were studied for various glucose concentrations at constant air and liquid flow rates. Increasing glucose concentration increased the biomass concentration thus resulting in an increase in the volumetric oxygen uptake rate. The volumetric mass transfer coefficient, k_La, however, decreased with increasing glucose concentration. It was observed that the growth of S cerevisiae in the CDCR would fit the classical Monod kinetics and the maximum specific growth rate was determined to be 0.545 h⁻¹. © 2000 Society of Chemical Industry     

Modeling of vanillin production in a structured bubble column reactor

Vanillin is an important flavour. Semi-synthetic vanillin can be produced by the oxidation of lignin. Experimental studies leading to vanillin production in a batch reactor and a structured bubble column reactor (SBCR) lead us to the conclusion that the SBCR could have non-idealities such as dispersion. The radial and axial liquid-phase dispersion within the packed criss-crossing sandwich structures of Mellapak-750Y had been studied. A 2D model accounting for axial and radial velocities and dispersion was formulated and solved. The model predictions were compared with that of an experimental residence time distribution curve. The axial dispersion coefficient of the liquid phase is of the same order of magnitude as the radial dispersion coefficient. The reaction kinetics available in literature is adopted for the present study. Model for the SBCR was formulated and simulated using commercial modeling software. Simulation experiments were conducted in a SBCR. The effect of the following parameters on the yield of vanillin is studied: lignin concentration, lignin molecular weight, oxygen partial pressure and reaction temperature. It can be said that lignin molecular weight is a crucial parameter in vanillin production.     

Reactors for ethanol production using immobilised yeast cells

Ethanol production by immobilised yeast cells in packed-bed column reactors was significantly affected by the hold-up of CO₂ produced during the fermentation. Compartmentalisation of the reactor minimises CO₂ hold-up and prevents flotation of immobilised cell beads during operation and bead rupture during shut-down conditions. In a reactor of dimensions 2·2 × 60 cm, a rate of ethanol production of 5·11 g h^?1 at a dilution rate of 1·27 h^?1 was achieved, when 18% (w/v) glucose solution was fed at the bottom at pH 5·5 and temperature 33–35°C. In larger reactors of sizes 4 ×; 40 cm and 8 × 80 cm the rates of ethanol production and CO₂ hold-ups were 5·11 and 5·37 g h^?1 and 48·66% and 40·66% and 40·79% of the void volume at dilution rates of 1·27 h^?1 and 1·67 h¹, respectively. The CO₂ hold-ups in column reactors (4 × 40 cm) held in inclined (43° from horizontal) or horizontal positions were 41·33% and 46·67% of the void volume, respectively. Double and triple series reactors (each of dimensions 2·2 × 60 cm) showed better performance than a single verticle reactor (2·2 × 60 cm).     

Increase of ethanol productivity in an airlift reactor with a modified draught tube

Static mixers were introduced in the draught tube of a three-phase, concentric tube type airlift bioreactor, resulting in a 30% increase in ethanol productivity during glucose fermentation with a highly flocculent strain of Saccharomyces cerevisiae. Increased productivity was obtained as a consequence of the floe size reduction provoked by the new design of the draught tube and of the smaller applied aeration rates, allowing a higher dilution rate to be used. Steady state data at different dilution rates were measured for both systems and the results were compared in terms of specific consumption / production rates and ethanol productivity. An approach based on heterogeneous catalysis principles was used in order to consider the presence of porous yeast flocs. Total glucose conversion was achieved at a dilution rate of 0.34 h^?1. The smaller floe size contributed to the higher observed reaction rates by reducing diffusional limitations inside the flocs. The respiratory quotient had a constant value (around 23) at all dilution rates, meaning that the metabolic state of the cells in the flocs remained constant, having a strong fermentative metabolism.     

Facilitated mass transfer in a packed-bed immobilized-cell reactor by using an organic solvent as substrate reservoir

The production of propene oxide from propene and oxygen by non-growing cells entrapped in calcium alginate was used to study the behaviour of a packed-bed immobilized-cell reactor operated with an organic solvent as the substrate reservoir. As a result of the high solubility of propene in the solvent used, n-hexadecane, oxygen was considered to be the limiting substrate. Dilution of the biocatalyst bed with small glass particles appeared necessary to attain a high liquid/solid contacting efficiency between the hydrophilic gel particles and the hydrophobic solvent. The bed dilution had the advantage of avoiding bed compaction and reducing pressure drops. The use of an organic solvent as the transport medium prevented oxygen depletion along the length of the packed-bed reactor. This eliminated the need for a separate gas phase in the bioreactor. A mathematical reactor model was developed to describe the combined effects of contacting pattern and external and internal diffusion limitations on the instrinsic kinetics of the immobilized cells. Experiments with the packed-bed immobilized-cell reactor were performed using an aqueous solution or n-hexadecane as the reaction medium. Predicted oxygen conversions compared favourably to the observed values without the need for fitting factors.     

Biological nutrient removal in a sequencing batch reactor using ethanol as carbon source

BACKGROUND: When organic matter is limiting for biological nutrient removal (BNR) from wastewater, external organic carbon can be added to a wastewater treatment plant (WWTP). This increases the overall treatment cost, so the choice of substrate is critical. The effect of using ethanol as the carbon source for BNR is investigated. RESULTS: The results clearly showed that using ethanol as a carbon source is a promising strategy for removing nutrients from wastewater. Effluent concentrations of 3.0 mg total nitrogen (TN) L^?1 (96% N removal efficiency) and 0.05 mg phosphate (P‐PO₄) L^?1 (99.9% P removal efficiency) were obtained. Furthermore, tests performed in order to identify the carbon source used by polyphosphate‐accumulating organisms (PAOs) showed that the phosphorus release/carbon uptake ratio using ethanol (0.41 mmol P mmol^?1 C) was slightly lower than that with acetate (0.50 mmol P mmol^?1 C) but close to that with propionate (0.42 mmol P mmol^?1 C). CONCLUSION: Therefore, taking into account the results presented for ethanol‐acclimatised biomass and the fact that the cost of ethanol is lower than that of acetate or propionate, ethanol can be considered as an alternative carbon source if one is needed in a WWTP. Copyright © 2007 Society of Chemical Industry     

Fuel ethanol production from concentrated food waste hydrolysates in immobilized cell reactors by Saccharomyces cerevisiae H058

BACKGROUND: Continuous ethanol fermentation of concentrated food waste hydrolysates has been studied. The process was carried out in an immobilized cell reactor with beads of calcium‐alginate containing immobilized Saccharomyces cerevisiae H058 at temperature 30 °C and pH 5.0. RESULTS: The total residual sugar decreased with increase of hydraulic retention time (HRT) under various reducing sugar concentrations. Ethanol production by immobilized cells increased with increase in HRT, regardless of the substrate concentrations employed. The highest ethanol concentration of 89.28 g L^?1 was achieved at an HRT of 5.87 h and reducing sugar concentration of 200 g L^?1. At an HRT of 1.47 h, the maximum volumetric ethanol productivity of 49.88 g L^?1 h^?1 and the highest ethanol yield of 0.48 g g^?1 were achieved at reducing sugar concentration of 160 and 200 g L^?1, respectively. The difference between the fresh and the 30‐day Ca–alginate immobilized cell was also shown by scanning electronic micrographs of beads taken from their outer and inner surfaces. CONCLUSIONS: Continuous ethanol production from concentrated food waste hydrolysates using immobilized yeast cells is promising in view of the high ethanol productivity obtained at relatively high conversion and excellent reactor stability. Copyright © 2011 Society of Chemical Industry     

填充床反应器中酶法合成生物蜡酯

研究了填充床式反应器酶法合成生物蜡酯的生产工艺。以大豆油、十六醇为原料,在石油醚体系中,使用实验室自制的固定化Candida sp.99-125为催化剂。对操作参数,如填充高度、进料速度、固定化酶用量、底物摩尔比进行了研究。结果表明,固定化酶质量为47 g,填充高度40 cm（内径3.5 cm）,油醇摩尔比1∶2.4,以4 mL/min速度进料保留时间4 h,产率可达83%。固定化酶在使用16批时,产率仍保持在70%以上。同时,对于填充床的填充方式作了初步探索。