Improvement of heat removal in solid‐state fermentation tray bioreactors by forced air convection

BACKGROUND: Heat removal is one of the major constraints in large‐scale solid‐state fermentation (SSF) processes. The effect of internal air circulation by forced convection on heat and water transfer has not been studied in SSF tray bioreactors. Formulation of a mathematical model for SSF requires a good estimation of the mass and heat transfer coefficients. RESULTS: A stainless steel tray bioreactor (80.6 L capacity) was used. Aspergillus niger C28B25 was cultivated under SSF conditions on an inert support. Temperature, moisture content, biomass and substrate concentrations were measured. Water and energy integral balances were used to estimate the heat and mass transfer coefficients involved in the process. The Reynolds number (N_Re) in the headspace of the tray bioreactor ranged from 2.5 to 2839, which increased the global heat transfer coefficient from 4.2 to 6.9 (W m^?2 K^?1) and the mass transfer coefficient from 1.0 to 2.1 (g m^?2 s^?1). Mathematical model predictions of the temperature and moisture content of the fermentation bed showed a high goodness‐of‐fit with the experimental results. CONCLUSIONS: This is the first report describing the effect of N_Re of air in the headspace of a SSF tray bioreactor on the heat and mass transfer coefficients and temperature regulation in SSF. Copyright © 2011 Society of Chemical Industry     

Investigating the use of cooling surfaces in solid‐state fermentation tray bioreactors: modelling and experimentation

The effect of wall cooling in tray‐type solid‐state fermenters was investigated by cultivation of Aspergillus niger ATCC 10 864 on wheat bran. Temperature, moisture, pH and glucoamylase activity in the bed were monitored. Application of the heat exchanger plate reduced the overall water loss but increased the heterogeneity of moisture distribution in the bed. Moisture content increased markedly close to the heat transfer plate while the upper regions of the bed dried out. The thermal conductivity of the bed was measured to be 0.19 W m^?1 K^?1. At these conditions and depending on the air flow rate, 58–82% of the metabolic heat was removed via conduction towards the plate. A mathematical model was developed to describe the behaviour of the system. Model predictions were in good agreement with the experimental results. Diffusion coefficients of water vapour and oxygen in the bed were estimated to be around 1.3 × 10^?5 m² s^?1 and 1 × 10^?5 m² s^?1 respectively. Based on these values the mathematical model describes the way oxygen and water vapour diffusion influences biomass growth and moisture distribution in the bed. Copyright © 2004 Society of Chemical Industry     

Value‐added bioconversion of biomass by solid‐state fermentation

The value‐added bioconversion of biomass is necessary due to the depletion of fossil fuels and deterioration of the global environment situation. Based on the analysis of characteristics of solid materials and the applicability of solid agro‐industrial residues used as feedstock for solid‐state fermentation (SSF), the authors established a value‐added bioconversion system for biomass using the key technology SSF. This article gives an overview of biomass bioconversion by SSF and the corresponding advances achieved in recent years. Copyright © 2012 Society of Chemical Industry     

Penicillium commune spore production in solid‐state fermentation of coffee pulp at laboratory scale and in a helical ribbons rotating reactor

Penicillium commune was grown on coffee pulp (CP) by solid‐state fermentation (SSF). The effects of the duration of CP thermal treatment and the effects of incubation temperature on spore production yield were studied at laboratory scale. The effect of mixing during fermentation was assayed at pilot plant scale in a 70 L stainless steel non‐aseptic reactor equipped with helical ribbons for mixing solids. For thermal treatments of CP at 121 °C for 10, 20, 30 and 40 min, no significant difference in spore production yield was observed. Maximum sporulation yield was found at 25 °C; when the incubation temperature was higher than 30 °C, the sporulation yield decreased significantly. A spore production yield of 3.7 × 10⁹ spores g^?1 dry CP was obtained when continuous mixing (0.25 rpm) was used at pilot plant scale; however, a decrease in spore yield (1.4 × 10⁹ spores g^?1 dry CP) was observed under static conditions. Spore production was not affected when a scale factor between 79 and 105 was assayed from laboratory to pilot plant; at this level, the productivity obtained was 3.1 × 10⁷ spores g^?1 dry CP h^?1. This value is similar to that found in other reports using natural substrates but working at a smaller scale. Copyright © 2006 Society of Chemical Industry     

Optimization of inulinase production by solid‐state fermentation in a packed‐bed bioreactor

BACKGROUND: This work is focused on inulinase production by solid‐sate fermentation (SSF) using sugarcane bagasse, corn steep liquor (CSL), pre‐treated cane molasses, and soybean bran as substrates in a 3‐kg (dry basis) packed‐bed bioreactor. SSF was carried out by the yeast Kluyveromyces marxianus NRRL Y‐7571 and response surface methodology was used to optimize the temperature, air flow rate and initial mass of cells. RESULTS: The optimum inulinase activity (436.7 ± 36.3 U g^?1 dry substrate) was obtained at 24 h at an inlet air temperature of 30 °C, air flow rate 2.2 m³ h^?1 and 22 g of cells for fermentation. Inulinase productivity at these conditions was 18.2 U gds^?1 h^?1. Kinetic evaluation at the optimized conditions showed that the maximum inulinase production was verified at 24 h of fermentation. The carbon dioxide and the metabolic heat generation are directly associated with the consumption of total reducing sugars present in the medium. CONCLUSION: The high productivity achieved in this work shows the technical viability of inulinase production by SSF in a packed‐bed bioreactor. Copyright © 2009 Society of Chemical Industry     

Protease production by Aspergillus oryzae in solid‐state fermentation using agroindustrial substrates

BACKGROUND: An inexpensive and readily available agroindustrial substrate such as rice bran can be used to produce cheap commercial enzymes by solid‐state fermentation. This work investigates the production of food‐grade proteases by solid‐state fermentation using readily available Thai rice bran. RESULTS: A local strain of Aspergillus oryzae (Ozykat‐1) was used to produce proteases. Rice bran used alone proved to have poor substrate morphology (insufficient porosity) for satisfactory solid‐state fermentation. A certain amount of wheat bran was necessary to improve the morphology of the substrate. The following variables affected protease production: substrate composition, initial moisture content and initial pH. A high protease activity (∼1200 U g⁻¹ dry solids) was obtained on a substrate that had a wheat bran to rice bran ratio of 0.33 by dry weight, a moisture content of 50%, initial pH of 7.5, and incubation temperature of 30 °C. CONCLUSION: Nutritionally, rice bran used alone was as good a substrate as mixed bran for producing protease, but rice bran had poor morphological characteristics for consistent fermentation. A substrate that had a wheat bran to rice bran ratio of 0.33 by dry weight was best for producing protease. Copyright © 2008 Society of Chemical Industry     

Growth of Rhizobium leguminosarum on peat in rotating bioreactors

The legume inoculant Rhizobium leguminosarum was grown on peat in roller bottles and a rotating drum bioreactor. Growth conditions were first determined using experiments in roller bottles. The best growth rate and cell count were obtained with peat containing 40% moisture (wet basis) and a volume fraction of moist peat of 0.3 in the roller bottle bioreactors. A cell count of 1.3 to 1.9 × 10⁹ CFU/g was achieved in 4 d or less, from an initial inoculum of 10⁶ CFU/g. In a rotating drum bioreactor, the growth of R.leguminosarum on peat with sucrose as the main carbon source was completed after 4 d. The majority of growth was in the first 2 d, based on carbon dioxide evolution. These results showed that growth of R. leguminosarum was more rapid in the rotating drum than in bags of peat, due to enhanced oxygen transfer.     

Solid‐liquid mass transfer in a rotary drum

The solid‐liquid mass transfer coefficient for slurries agitated in rotating drums with baffles was measured using the dissolution of β‐naphthol as a tracer in silica sand slurries. The effects of drum rotation rate (0.33 to 15 min^?1), slurry holdup (4.4% to 17%) and solids volume fraction (0 to 0.62) on the solid‐liquid mass transfer were investigated with a slurry particle diameter of 4.6 × 10^?4 m. Mass transfer coefficients were corrected for the effect of particle shrinkage due to dissolution of the tracer. The mass transfer coefficient increased with increasing rotational speed of the drum from 0.005 to 0.045 mm.^5‐1. Two types of slurry motion were observed; well mixed slurry flowing over the baffles and segregation of solids on the baffles. The mass transfer coefficients from the present study, along with literature data, correlated with the Froude number to the 0.36 power, for Froude numbers from 10^?6 to 10^?1.     

A comprehensive model for solid‐state polycondensation of poly(ethylene terephthalate): Combining kinetics with crystallization and diffusion of acetaldehyde

A comprehensive mathematical model was established by considering the main and side reactions for solid‐state polycondensation of poly(ethylene terephthalate). The effect of temperature on chain mobility was used to estimate the rate constants of chemical reactions. The polymer crystalline fraction was modeled as containing only repeat units, thus concentrating end groups and condensates in the amorphous fraction. The diffusion coefficient of acetaldehyde was calculated by the model. The simulation results of this comprehensive model were validated by experimental data reported in literature. The model predictions were important clues for further experimental study on poly(ethylene terephthalate) solid‐state polycondensation. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 83: 3133–3144, 2002; DOI 10.1002/app.10113     

葡萄酒胶发酵中的内热源和传热特性

葡萄酒发酵过程放热量大,控温发酵是高品质葡萄酒酿造中的一项主要技术措施。对葡萄酒发酵过程的放热特性进行了实验研究,首先在没有加入温控的情况下,进行红葡萄酒胶的自然发酵实验,得到其产生热量的变化关系,即确定发酵过程中变化的内热源项。然后进行控温发酵实验,考虑其发酵内热源项,进行了非稳态传热分析,获得了发酵过程中温度分布的表达式,并对发酵过程中温度分布进行了数值计算,与实验结果吻合较好。     

Production of α‐amylase under solid‐state fermentation utilizing coffee waste

Coffee industry substrates such as coffee pulp, coffee cherry husk, silver skin, spent coffee and mixtures of these coffee wastes (MC) were evaluated for their efficacy as sole carbon source for the synthesis of α‐amylase in solid‐state fermentation (SSF) using a fungal strain of Neurospora crassa CFR 308. For SSF with coffee pulp and with MC, α‐amylase activity of 3908 U g^?1 ds (units per gram of dry substrate) and 3870 U g^?1 ds, respectively, was observed. Parameters such as moisture (60%), pH (4.6), temperature (28 °C), particle size (1.0 mm), inoculum size (10⁷ spores g^?1 ds), and fermentation time (5 days) were optimized for enzyme synthesis, wherein 4981 and 4324 U g^?1 U g^?1 ds of α‐amylase activity was obtained in SSF with coffee pulp and MC, respectively. The enzyme production was further improved when the substrates were subjected to pre‐treatment by steaming. Accordingly, maximum α‐amylase activity of 7084 U g^?1 ds and 6342 U g^?1 ds was obtained with steam‐pretreated coffee pulp and MC, respectively, demonstrating them to be excellent sole carbon sources for synthesis of α‐amylase production. Copyright © 2009 Society of Chemical Industry     

Statistical optimization of process parameters for the production of vanillic acid by solid‐state fermentation of groundnut shell waste using response surface methodology

BACKGROUND: Vanillic acid is a flavoring agent and also serves as precursor for vanillin production. Culture medium and fermentation condition for the single step production of vanillic acid from Phanerochaete chrysosporium using lignocellulosic waste as a substrate under solid state fermentation (SSF) were optimized using response surface methodology. RESULTS: The process parameters were chosen by borrowing methodology, and L‐asparagine, pH and moisture content of the solid medium during SSF were identified as the most significant variables. The optimum value of selected variable and their mutual interactions were determined by response surface methodology. The result demonstrated that a yield of 73.58 mg vanillic acid g^?1 substate was predicted under optimum conditions (L‐asparagine 5.98 mmol L^?1 (2.37 mg g^?1 groundnut shell), pH of solid medium 4.51 and moisture content 74.83%). The predicted response was experimentally validated and resulted in a maximum vanillic acid yield of 73.69 mg g^?1 after 8 days of SSF. CONCLUSION: The optimization of fermentation variables resulted in a maximum 10‐fold increase in vanillic acid yield compared with that observed under sub‐optimal conditions (from 7.2 mg g^?1 to 73.69 mg g^?1). Copyright © 2011 Society of Chemical Industry     

Design of different bioreactor configurations: application to ligninolytic enzyme production in semi‐solid‐state cultivation

The production of ligninolytic enzymes by Phanerochaete chrysosporium BKM‐F‐1767 (ATCC 24725) in laboratory‐scale bioreactors was studied. The cultivations were carried out in semi‐solid‐state conditions, employing corncob as carrier, which functioned both as a place of attachment and as a source of nutrients. Several bioreactor configurations were investigated in order to determine the most suitable one for ligninolytic enzyme production: a 1‐dm³‐static‐bed bioreactor, a 1‐dm³‐static‐bed bioreactor with air diffusers into the bed, a 0.5‐dm³‐static‐bed bioreactor with air diffusers into the bed and a tray bioreactor. Although the static‐bed configurations produced maximum individual lignin peroxidase (LiP) activities about 400 U dm⁻³ (1.0‐dm³ bioreactor) and about 700 U dm⁻³ (0.5‐dm³ bioreactor), manganese‐dependent peroxidase (MnP) was not detected throughout the cultures. Nevertheless, the tray configuration led to maximum individual MnP and LiP activities of about 200 U dm⁻³ and 300 U dm⁻³, respectively. Therefore, this configuration is the most adequate of the different bioreactor configurations tested in the present work, since the ligninolytic complex formed by MnP and LiP is more efficient for its application to bio‐processing systems. In addition, the results indicated the influence of the oxygen in ligninolytic enzyme production. © 2001 Society of Chemical Industry     

DEM study of granular flow characteristics in the active and passive regions of a three‐dimensional rotating drum

Three‐dimensional modeling of the solid motion in a lab‐scale rotating drum has been conducted via the discrete element method. After validating the simulated results with available experimental data, the active‐passive interface was identified, following which particle‐scale information in these two regions, in particular the influences of fill level and rotating velocity, were obtained. The results demonstrate that: (1) the total number of particles in the passive region is three times that in the active, (2) the transverse and axial velocities span a wider range in the active region, with the transverse values being greater, (3) the collision force is much higher in the active region, with the greatest magnitudes in the y direction relative to that in the x and z directions, (4) particle displacements are generally lower and have a narrower distribution in the active region, (5) the local solid residence time (SRT) distribution profiles are similar axially in that the highest SRT magnitudes are at the center region of the bed, while the other parts of the bed have uniform SRT magnitudes. © 2016 American Institute of Chemical Engineers AIChE J, 62: 3874–3888, 2016     

Inoculum strategies for Penicillium simplicissimum lipase production by solid‐state fermentation using a residue from the babassu oil industry

Two alternative inoculation strategies for lipase production by the fungus Penicillium simplicissimum were tested in solid‐state fermentation using a residue from the babassu oil industry (babassu cake). Conventional spore inoculation was compared with fungal pellets grown in liquid medium and with inocula consisting of fermented cake. Fungal pellets delayed lipase production whereas fermented cake accelerated enzyme synthesis, yielding a productivity of 0.45 U g^?1 h^?1, which is equivalent to the highest values obtained with conventional inocula. Therefore, a 2² factorial design was used to determine the best conditions for lipase production with fermented cake as inoculum strategy, varying the inoculum propagation time and inoculum concentration. Lipase activity and productivity reached 30 U g^?1 and 0.63 U g^?1 h^?1, respectively, with 10% inoculum and 36 h. Thus, fermented cake inocula increased production 1.5‐fold with 10 times fewer spores than in conventional inoculation, indicating that fermented solids are an interesting alternative for inoculum development in solid‐state fermentation, mainly for large‐scale processes. Copyright © 2007 Society of Chemical Industry