High yeast concentration in continuous fermentation with cell recycle obtained by tangential microfiltration

Summary Continuous fermentation fed by 150 kg/m³ of glucose with total cell recycling by tangential microfiltration enabled yeasts concentration of 300 kg/m³ (dry weight) to be reached with a dilution rate of 0,5h^–1 and a cell viability greater than 75%. The stability of this system was tested for 50 residence times of the permeate. The method can be used both for the production of cell concentrates and for high rates of metabolite production.Nomenclature D. W. dry weight - X_T (kg/m³) total cell concentration D.W. - X_V (kg/m³) viable cell concentration D.W. - V viability of cell culture in per cent of total cell concentration - S (kg/m³) glucose concentration - P (kg/m³) ethanol concentration - D (h) dilution rate - R (kg/kg) fermentation yield - (h) specific growth rate - vp(kg/kg/h) specific alcohol production rate - (m) yeast size - (kg/kg) kg of intracellular water per kg of dry cells     

Broth recycle in a yeast fermentation

Fermentation is a water-intensive process requiring treatment of large amounts of effluent broth. It is desirable to increase the ratio of product produced to the volume of effluent by minimizing the discharge of effluent from the fermentation process. A study of recycling spent fermentation process. A study of recycling spent fermentation broth for the subsequent fermentation was carried out with Apiotrichum curvatum an oleaginous yeast, as the working culture. Spent broth from a defined medium was recycled t replace as much as 75% of the water and salts for subsequent batches and this was repeated for seven sequential batches without affecting cell mass and lipid production. A 64% vlume reduction of wastewater was achieved in this manner. However, when using whey permeate as the medium, lipid production dropped after three consecutive recycle operations at 50% recycle, and after two consecutive recycle operations at 75% and 100% recycle. Accumulation of ions in the broth appeared to be responsible for the inhibition. An ion exchange step was able to eliminate the ion buildup and restore fermentation performance. (c) 1994 John Wiley & Sons, Inc.     

Competitive yeast fermentation with selective flocculation and recycle

Continuous fermentations were carried out involving competition between two strains of Saccharomyces cerevisiae. One of the strains has a lower specific growth rate and is very flocculent, whereas the fastergrowing strain is nonflocculent. The product stream from the chemostat was fed into an inclined settler where the flocculent strain was partially separated from the nonflocculent strain as a result of the higher sedimentation rate of the flocculent cells. The underflow from the inclined settler, which was concentrated and enriched with flocculent cells, was recycled to the chemostat. When no recycle was used, the fastergrowing, nonflocculent yeast rapidly overtook the culture. With selective recycle, however, the experiments demonstrated that the slower-growing flocculent yeast could be maintained as the dominant species. A theoretical development is also presented in order to describe the competition between two strains in the bioreactor-settler system. The concept of selective recycle via selective flocculation and sedimentation offers a possible means of maintaining unstable recombinant microorganisms in continuous fermentations.     

Fermentation coupled with microfiltration: kinetics of ethanol fermentation with cell recycle

Cell recycle by microfiltration was used in yeast alcoholic fermentation in continuous operation. Toxins were proved to be washed by increasing dilution rate. — Specific ethanol production rate followed an exponential inhibition equation, which is function of both biomass concentration and dilution rate. — Productivity is shown to be 40 times greater than in conventional continuous operation.     

Heterolactic fermentation by a homofermentative Lactobacillus sp. during glucose limitation in anaerobic continuous culture with complete cell recycle

E. BORCH, H. BERG AND O. HOLST. 1991. The homofermentative Lactobacillus sp. 93 SMRICC 235 was grown anaerobically in batch culture and subsequent continuous culture, with complete cell recycle at pH 6.0 and 25^.C, on a semi-defined medium. During cell recycle culture the biomass was concentrated in the fermenter to a final dry weight of 37 g/1 and a viable count of 10.6 log cfu/ml. The corresponding final values in batch culture were 2.4 g/1 and 9.3 log cfu/ml. A switch from homo- to heterolactic fermentation was observed during starvation, due to glucose depletion in the cell recycle culture. High levels of acetate and formate were produced in addition to ethanol. Amino acid profiles of hydrolysed samples showed extensive utilization of amino acids, particularly in cell recycle culture. Sulphide was produced during cell recycle culture. The change from homo- to heterolactic fermentation observed during semi-starvation is likely to affect the properties of lactobacilli as spoilage bacteria of meat and meat products, as well as starter cultures.     

Scale-up effects on kinetic parameters and on predictions of a yeast recycle continuous ethanol fermentation model incorporating loss of cell viability

The scale-up effects on kinetic parameters and on predictions of a yeast recycle continuous ethanol fermentation model incorporating loss of cell viability were evaluated. The average level of cell viability estimated for large scale was similar to that estimated for small scale, although with a major standard deviation. The values of specific rate of cell viability loss were equal for the two scales. These results were due to the utilization of the same aeration rate for both scales, one of the main factors for cell-viability maintenance. The kinetic parameters were not significantly affected by the scale-up of the fermentation process. Major differences were observed for the maximum specific growth rate and for maximum ethanol concentrations for which, growth and ethanol production are totally inhibited. The scale-up did not result in lack of fit of the mathematical model to the experimental data.     

Acetonobutylic fermentation: improvement of performances by coupling continuous fermentation and ultrafiltration

The technology of coupling ultrafiltration and fermentation has been tested with the acetonobutylic fermentation in continuous mode. The device developed was sterilizable by steam and permitted drastic cleaning of the ultrafiltration (UF) membrane without interrupting the continuous fermentation. It has been shown to be an easily operated and reliable experimental tool for studying high-cell-density cultures and inhibition phenomena. With total recycle of biomass, a dry weight concentration of 125 g/L was attained, which greatly enhanced the volumetric solvent productivity of acetonobutylic fermentation in averaging 4. 5 g/L h for significant periods of time (>70 h) and maintaining solvent concentration and yield at acceptable levels.     

Butyric fermentation: metabolic behaviour and production performance of Clostridium tyrobutyricum in a continuous culture with cell recycle

Summary Two physiological characteristics of butyric fermentation, inhibition by the acids produced, butyrate and acetate, and dependence on the growth rate of the distribution of these acids, prompted a study of butyrate production in a continuous fermentation system with cell recycle by microfiltration. The influence of the main operating parameters, glucose input (feed concentration and dilution rate) and bleed dilution rate on production of acids and biomass was studied. The performance of the system greatly exceeded the results obtained in batch and simple continuous fermentations as a high productivity for butyrate (9.5 g l^–1 h^–1) was achieved whilst retaining a satisfactory concentration of butyrate (29.7 g l^–1) and low acetate production (0.6 g l^–1) at a cell biomass concentration of 35 g l^–1. Cell growth rate was found to be a critical parameter for performance stability as oscillations in metabolic activity due to inhibition by acids were observed at bleed dilution rates below 0.016 h^–1.Offprint requests to: J. P. Vandecasteele     

Performance of a two-stage fermentor with cell recycle for continuous production of lactic acid

The performasnce of a recycle two-stage fermentor with cell separators after each stage is analyzed numerically for continuous production of lactic acid. In this system, the bleed broth withdrawn from the first stage is provided to the second fermentor to reuse viable cells in the bleed. Biological rate expressions and parametric values are taken from the literature. The effects of operating parameters on the concentrations of total and viable cells, substrate and product in each stage, the lactic acid productivity and the substrate conversion are examined and discussed. With respect to overall productivity and conversion, it is found that the present fermentor system is more efficient than a conventional chemostat fermentor with cell recycle.     

Effect of cell recycle on continuous butanol-acetone fermentation with Clostridium acetobutylicum under phosphate limitation

Summary An overflow filtration unit for cell recycle with Clostridium acetobutylicum was developed. A cellulose-triacetate ultrafiltration membrane with a cut-off volume of 20 000 MW was found to work best. C. acetobutylicum was grown in continuous culture under phosphate limitation (0.74 mM) at a pH value of 4.4 with cell recycle, the cell dry weight in the culture vessel reached 13.1 g/l at a dilution rate of D=0.10 h^-1 and 37°C. 377 mM of glucose were fermented to 190 mM butanol, 116.2 mM acetone and 25.8 mM ethanol. Total acids were 47.6 mM. The butanol productivity was 1.41 g/l/h. At a dilution rate of 0.40 h^-1 the butanol productivity was increased to 4.1 g/l/h but glucose consumption was decreased to 285 mM and butanol, acetone and ethanol production to 138.2, 97.5, 16.5 mM, respectively.     

L-Sorbose production in a continuous fermenter with and without cell recycle

The kinetics of continuous l-sorbose fermentation using Acetobacter suboxydans with and without cell recycle (100%) were investigated at dilution rates (D) of 0.05, 0.10, 0.15 and 0.3 h^–1. The biomass and sorbose concentrations for continuous fermentation without recycle increased as the dilution rate was increased from 0.05 to 0.10 h^–1. A maximum biomass concentration of 8.44 g l^–1 and sorbose concentration of 176.90 g l^–1 were obtained at D=0.10 h^–1. The specific rate of sorbose production and volumetric sorbose productivity at this dilution rate were 2.09 g g^–1 h^–1 and 17.69 g l^–1 h^–1. However, on further increasing the dilution rate to 0.3 h^–1, both biomass and sorbose concentrations decreased to 2.93 and 73.20 g l^–1 respectively, mainly due to washout of the reactor contents. However, the specific rate of sorbose formation and volumetric sorbose productivity at this dilution rate increased to 7.49 g g^–1 h^–1 and 21.96 g l^–1 h^–1 respectively. Continuous fermentation with 100% cell recycle served to further enhance the concentration of biomass and sorbose to 28.27 and 184.32 g l^–1 respectively (in the reactor at a dilution rate of 0.05 h^–1). Even though, there was a decline in the biomass and sorbose concentrations to 6.8 and 83.40 g l^–1 at a dilution rate of 0.3 h^–1, the specific rates of sorbose formation and volumetric sorbose productivity increased to 3.67 g g^–1h^–1 and 25.02 g l^–1 h^–1.     

Semi-continuous ethanolic fermentation using a novel yeast settling and recycle technique

Summary A novel technique for the rapid settling of yeast cells is outlined. An inert, high density powder is added to a yeast suspension and the pH of the suspension is switched rapidly from 4.5 (fermentation pH) to 8.0. Large, rapid settling flocs of yeast are formed immediately. This technique has been applied to the recycling of yeast from an ethanolic fermentation.     

Propionic acid fermentation: improvement of performances by coupling continuous fermentation and ultrafiltration

The present paper presents a study of propionic acid production from whey by using Propionibacterium acidipropionici in batch and continuous fermentation with cell recycle. The experimental investigation is carried through with a biomass concentration (DW) of 112kg/m³. The highest propionic acid productivity is 2.14 kg/(m³ h). Biomass concentration is 9 times as high, propionic acid productivity 6 times as high as compared to batch results.     

A continuous fermentation technique for studying the kinetics of sugar uptake by baker's yeast

1. Solutions of glucose, maltose or other sugars were pumped at controlled rates into a yeast suspension and the extracellular sugar concentration was determined. The technique was especially suitable for studying the kinetics of fermentation at low rates of sugar utilization. At high rates the fermentation system was unstable. 2. Glucose fermentation was fitted by a model in which a diffusion barrier with first-order kinetics is interposed between the environment and the site of hexokinase. 3. Aerobic conditions affected the fermentation enzyme system but not the diffusion mechanism. 4. The kinetics of maltose fermentation at low rates approximated to those of the hydrolysis of maltose by the enzyme maltase, as studied in suspensions of broken cells.     

Enzyme production in a cell recycle fermentation system evaluated by computer simulations

Enzyme production in a cell recycle fermentation system was studied by computer simulations, using a mathematical model of -amylase production by Bacillus amyloliquefaciens. The model was modified so as to enable simulation of enzyme production by hypothetical organisms having different production kinetics at different fermentation conditions important for growth and production. The simulations were designed as a two-level factorial assay, the factor studied being fermentation with or without cell recycling, repression of product synthesis by glucose, kinetic production constants, product degradation by a protease, mode of fermentation, and starch versus glucose as the substrate carbon source.The main factor of importance for ensuring high enzyme production was cell recycling. Product formation kinetics related to the stationary growth phase combined with continuous fermentation with cell recycling also had a positive impact. The effect was greatest when two or more of these three factors were present in combinations, none of them alone guaranteeing a good result. Product degradation by a protease decreased the amount of product obtained; however, when combined with cell recycling, the protease effect was overshadowed by the increased production. Simulation of this type should prove a useful tool for analyzing troublesome fermentations and for identifying production organisms for further study in integrated fermentation systems.List of Symbols a proportionality constant relating the specific growth rate to the logarithm of G (h) - a ₁ reaction order with respect to starch concentration - a ₂ reaction order with respect to glucose concentration - c starch concentration (g/l) - c ₀ starch concentration in the feed (g/l) - D dilution rate (h^–1) - e intrinsic intracellular amylase concentration (g product/g cell mass) - E extracellular amylase concentration (g/l) - F volumetric flow rate (l/h) - G average number of genome equivalents of DNA/cell - K ₁ intracellular repression constant - K ₂ intracellular repression constant - K _s Monod saturation constant (g/l) - k ₃ product excretion rate constant (h^–1) - k _I translation constant (g product/g mRNA/h) - k _d first order decay constant (h^–1) - k _dw first order decay constant (h^–1) - k _gl rate constant for glucose production (g/l/h) - k _{m, dgr} saturation constant for product degradation (g/l) - k _st rate constant for starch hydrolysis (g/l/h) - k _t1 proportionality constant for amylase production (g mRNA/g substrate) - k _t2 proportionality constant for amylase production (g mRNA *h/g substrate) - k _w protease excretion rate constant (h^–1) - k _wt1 proportionality constant for protease production (g mRNA/g substrate) - k _wt2 proportionality constant for protease production (g mRNA *h/g substrate) - k _wI translation constant (g protease/g mRNA/h) - m maintenance coefficient (g substrate/g cell mass/h) - n number of binding sites for the co-repressor on the cytoplasmic repressor - Q repression function, K₁/K₂ less than or equal to 1.0 - Q _w repression function, K₁/K₂ less than or equal to 1.0 - r intrinsic amylase mRNA concentration (g mRNA/g cell mass) - r _m intrinsic protease mRNA concentration (g mRNA/g cell mass) - R _ex retention by the filter of the compounds x=: C starch, E amylase, or S glucose - R _t amylase transport rate (g product/g cell mass/h) - R _wt protease transport rate (g protease/g cell mass/h) - R _s rate of glucose production (g/l/h) - R _c rate of starch hydrolysis (g/l/h) - S ₀ feed concentration of free reducing sugar (g/l) - s extracellular concentration of reducing sugar (g/l) - t time (h) - V volume (1) - w intracellular protease concentration (g/l) - W extracellular protease concentration (g/l) - X cell mass concentration (dry weight) (g/l) - Y yield coefficient (g cell mass/g substrate) - substrate uptake (g substrate/g cell mass/h) - specific growth rate of cell mass (h^–1) - _d specific death rate of cells (h^–1) - _m maximum specific growth rate of cell mass (h^–1) - _m,dgr maximum specific rate of amylase degradation (h^–1) This study was supported by the Nordic Industrial Foundation Bioprocess Engineering Programme and the Center for Process Biotechnology, The Technical University of Denmark.     

Xylitol conversion by fermentation using five yeast strains and polyelectrolyte-assisted ultrafiltration

Batch fermentations for xylitol production were conducted using Candida boidinii (BCRC 21432), C. guilliermondii (BCRC 21549), C. tropicalis (BCRC 20520), C. utilis (BCRC 20334), and P. anomala (BCRC 21359) together with a mixture of sugars simulating lignocellulosic hydrolysates as the carbon source. C. tropicalis had the highest bioconversion yield (Y_P/S) of 0.79 g g⁻¹ (g xylitol·g xylose⁻¹) over 48 h. Additional fermentations with C. tropicalis achieved Y_P/S values of 0.6 and 0.39 g g⁻¹ after 96 and 72 h using urea and soybean meal as the nitrogen sources, respectively. Ethanol and arabitol were also produced in all fermentation. Xylitol in the fermentation broth was recovered by cross-flow ultrafiltration. With prior application of 2 mg polydiallyl dimethylammonium chloride l⁻¹ on the membrane surface, protein in the permeate was reduced from 7.1 to 1.5 mg l⁻¹ after 2 h.     

Performance of a continuous bioreactor with immobilized yeast cells in the ethanol fermentation of molasses-stillage medium

Summary It is feasible to produce ethanol by continuous fermentation of molasses-stillage medium, without any supplementation, employing calcium alginate immobilized cells of Saccharomyces cerevisiae. High flow rates generated high values for the productivity; however, the percent substrate conversion decreases with the dilution rate.     

Comparative technoeconomic analysis of a softwood ethanol process featuring posthydrolysis sugars concentration operations and continuous fermentation with cell recycle

Economical production of second generation ethanol from Ponderosa pine is of interest due to widespread mountain pine beetle infestation in the western United States and Canada. The conversion process is limited by low glucose and high inhibitor concentrations resulting from conventional low‐solids dilute acid pretreatment and enzymatic hydrolysis. Inhibited fermentations require larger fermentors (due to reduced volumetric productivity) and low sugars lead to low ethanol titers, increasing distillation costs. In this work, multiple effect evaporation (MEE) and nanofiltration (NF) were evaluated to concentrate the hydrolysate from 30 g/l to 100, 150, or 200 g/l glucose. To ferment this high gravity, inhibitor containing stream, traditional batch fermentation was compared with continuous stirred tank fermentation (CSTF) and continuous fermentation with cell recycle (CSTF‐CR). Equivalent annual operating cost (EAOC = amortized capital + yearly operating expenses) was used to compare these potential improvements for a local‐scale 5 MGY ethanol production facility. Hydrolysate concentration via evaporation increased EAOC over the base process due to the capital and energy intensive nature of evaporating a very dilute sugar stream; however, concentration via NF decreased EAOC for several of the cases (by 2 to 15%). NF concentration to 100 g/l glucose with a CSTF‐CR was the most economical option, reducing EAOC by $0.15 per gallon ethanol produced. Sensitivity analyses on NF options showed that EAOC improvement over the base case could still be realized for even higher solids removal requirements (up to two times higher centrifuge requirement for the best case) or decreased NF performance. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 31:946–956, 2015     

Continuous acetone-butanol fermentation with high productivity by cell ultrafiltration and recycling

To increase the productivity of the acetone-butanol fermentation, a hollow-fiber ultrafilter is used to separate and recycle cells in a continuous fermentation ofClostridium acetobutylicum. Under partial cell recycling and at a dilution rate of 0.5 hr^–1, a cellular concentration of 20 g/l and a solvent productivity of 6.5 g/l.hr is maintained for several days at a total solvent concentration of 13 g/l.