Determination of carbon dioxide evolution rate using on-line gas analysis during dynamic biodegradation experiments

Online estimation of changing metabolic capacities in continuous Corynebacterium glutamicum cultivations growing on a complex sugar mixture

Model‐based state estimators enable online monitoring of bioprocesses and, thereby, quantitative process understanding during running operations. During prolonged continuous bioprocesses strain physiology is affected by selection pressure. This can cause time‐variable metabolic capacities that lead to a considerable model‐plant mismatch reducing monitoring performance if model parameters are not adapted accordingly. Variability of metabolic capacities therefore needs to be integrated in the in silico representation of a process using model‐based monitoring approaches. To enable online monitoring of multiple concentrations as well as metabolic capacities during continuous bioprocessing of spent sulfite liquor with Corynebacterium glutamicum, this study presents a particle filtering framework that takes account of parametric variability. Physiological parameters are continuously adapted by Bayesian inference, using noninvasive off‐gas measurements. Additional information on current parameter importance is derived from time‐resolved sensitivity analysis. Experimental results show that the presented framework enables accurate online monitoring of long‐term culture dynamics, whereas state estimation without parameter adaption failed to quantify substrate metabolization and growth capacities under conditions of high selection pressure. Online estimated metabolic capacities are further deployed for multiobjective optimization to identify time‐variable optimal operating points. Thereby, the presented monitoring system forms a basis for adaptive control during continuous bioprocessing of lignocellulosic by‐product streams.

Potential of off-gas analyses for sequentially operated reactors demonstrated on full-scale aerobic granular sludge technology

This work shows how more variables can be monitored with a single off-gas sampler on sequentially operated than on continuously fed and aerated reactors and applies the methods to data from a full-scale aerobic granular sludge reactor as a demonstration and to obtain insight in this technology. First, liquid-gas transfer rates were calculated. Oxygen (O₂) absorption and carbon dioxide (CO₂) emission rates showed comparable cyclic trends due to the coupling of O₂ consumption and CO₂ production. Methane (CH₄) emissions showed a stripping profile and nitrous oxide (N₂O) emissions showed two peaks each cycle, which were attributed to different production pathways. Secondly, aeration characteristics were calculated, of which the gradual improvement within cycles was explained by surfactants degradation. Thirdly, liquid phase concentrations were estimated from off-gas measurements via a novel calculation procedure. As such, an average influent CH₄ concentration of 0.7 g·m^-3 was found. Fourthly, reaction rates could be estimated from off-gas data because no feeding or discharge occurred during reaction phases. The O₂ consumption rate increased with increasing dissolved oxygen and decreased once nitrification was complete. Fifthly, greenhouse gas emissions could be derived, indicating a 0.06% N₂O emission factor. Sixthly, off-gas gave an indication of influent characteristics. The CO₂ emitted per kg COD catabolized corresponded with the TOC/COD ratio of typical wastewater organics in cycles with balanced nitrification and denitrification. High nitrogen removal efficiencies were associated with high catabolized COD/N ratios as estimated from the O₂ absorption. Finally, mass balances could be closed using off-gas O₂ data. As such, an observed yield of 0.27 g COD/g COD was found. All these variables could be estimated with a single sampler because aeration without feeding creates a more homogeneous off-gas composition and simplifies liquid-phase mass balances. Therefore, off-gas analyzers may have a broader application potential for sequentially operated reactors than currently acknowledged.

Noninvasive online monitoring of Corynebacterium glutamicum fed-batch bioprocesses subject to spent sulfite liquor raw material uncertainty

In this study the use of a particle filter algorithm to monitor Corynebacterium glutamicum fed-batch bioprocesses with uncertain raw material input composition is shown. The designed monitoring system consists of a dynamic model describing biomass growth on spent sulfite liquor. Based on particle filtering, model simulations are aligned with continuously and noninvasively measured carbon evolution and oxygen uptake rates, giving an estimate of the most probable culture state. Applied on two validation experiments, culture states were accurately estimated during batch and fed-batch operations with root mean square errors below 1.1 g L^-1 for biomass, 0.6 g L^-1 for multiple substrate concentrations and 0.01 g g^-1 h^-1 for biomass specific substrate uptake rates. Additionally, upon fed-batch start uncertain feedstock concentrations were corrected by the estimator without the need of any additional measurements. This provides a solid basis towards a more robust operation of bioprocesses utilizing lignocellulosic side streams.

Real-time characterization of mammalian cell culture bioprocesses by magnetic sector MS

Mammalian cell culture processes were characterized upon the analysis of the exhaust-gas composition achieved through the on-line integration of a magnetic sector MS analyser with benchtop bioreactors. The non-invasive configuration of the magnetic sector MS provided continuous evaluation of the bioreactor's exhaust gas filter integrity and facilitated the accurate quantification of O2 and CO2 levels in the off-gas stream which ensured preserved bioreactor sterility prior to cell inoculation and provided evidence of the ongoing cellular respiratory activity throughout the cultures. Real-time determination of process parameters such as the Respiratory Quotient (RQ) allowed for precise pin-pointing of the occurrence of shifts in cellular metabolism which were correlated to depletion of key nutrients in the growth medium, demonstrating the suitability of this technology for tracking cell culture process performance.

When and why do gradients of the gas phase composition and pressure affect liquid-gas transfer?

Gas bubbles are introduced in water to absorb or strip volatile substances in a variety of unit operations, for example during (waste)water treatment. To calculate the transfer rate of substances between the liquid phase and the gas phase, different assumptions have been made in literature regarding the gas phase composition and hydraulic pressure, which both vary along the reactor height. In this study, analytical expressions were derived for the total (macroscopic) liquid-gas transfer rate, using either the complete gradients of the mole fraction and pressure (comprehensive approach) or a uniform value, for one or both of them. Simulations with the comprehensive model were performed to understand the effect of the type of volatile substance and of the reactor design and operating conditions on the total liquid-gas transfer rate. These effects were found to be highly interactive and often non-linear. Next, the simulation results of the comprehensive model were compared with those from models that assume either a uniform mole fraction or a uniform pressure in the complete reactor volume. This illustrated that for soluble substances, the mole fraction gradient strongly affects the total liquid-gas transfer rate, while the pressure gradient became only important under operating conditions that promote stripping (i.e., for a high concentration in the liquid phase and low concentration in the inlet gas). For very poorly soluble substances, the pressure became more important under conditions that promote absorption. These results on the importance of the mole fraction and pressure gradients remained equally valid when explicitly considering a typical variation of the volumetric overall transfer coefficient (K_La) along the reactor height. Finally, a simple and fast procedure was made available through a spreadsheet to select appropriate simplifying assumptions in reactor or plant-wide models. By applying the procedure to oxygen (O₂), carbon dioxide (CO₂), methane (CH₄), nitrous oxide (N₂O) and nitrogen gas (N₂) in an aerobic biological wastewater treatment reactor, it was demonstrated that some common simplifications can lead to significant errors, for which corrections were proposed.

Considering the plug-flow behavior of the gas phase in nitrifying BAF models significantly improves the prediction of N2O emissions

Nitrifying biologically active filters (BAFs) have been found to be high emitters of nitrous oxide (N₂O), a powerful greenhouse gas contributing to ozone layer depletion. While recent models have greatly improved our understanding of the triggers of N₂O emissions from suspended-growth processes, less is known about N₂O emissions from full-scale biofilm processes. Tertiary nitrifying BAFs have been modeled at some occasions but considering strong simplifications on the description of gas-liquid exchanges which are not appropriate for N₂O prediction. In this work, a tertiary nitrifying BAF model including the main N₂O biological pathways was developed and confronted to full-scale data from Seine Aval, the largest wastewater resource recovery facility in Europe. A mass balance on the gaseous compounds was included in order to correctly describe the N₂O gas-liquid partition, thus N₂O emissions. Preliminary modifications of the model structure were made to include the gas phase as a compartment of the model, which significantly affected the prediction of nitrification. In particular, considering gas hold-up influenced the prediction of the hydraulic retention time, thus nitrification performances: a 3.5% gas fraction reduced ammonium removal by 13%, as the liquid volume, small in such systems, is highly sensitive to the gas presence. Finally, the value of the volumetric oxygen transfer coefficient was adjusted to successfully predict both nitrification and N₂O emissions.

A practical approach in bioreactor scale-up and process transfer using a combination of constant P/V and vvm as the criterion

Bioreactor scale-up is a critical step in the production of therapeutic proteins such as monoclonal antibodies (MAbs). With the scale-up criterion such as similar power input per volume or O₂ volumetric mass transfer coefficient ( kLa), adequate oxygen supply and cell growth can be largely achieved. However, CO₂ stripping in the growth phase is often inadequate. This could cascade down to increased base addition and osmolality, as well as residual lactate increase and compromised production and product quality. Here we describe a practical approach in bioreactor scale-up and process transfer, where bioreactor information may be limited. We evaluated the sparger kLa and kLaCO2 (CO₂ volumetric mass transfer coefficient) from a range of bioreactor scales (3-2,000 L) with different spargers. Results demonstrated that kLa for oxygen is not an issue when scaling from small-scale to large-scale bioreactors at the same gas flow rate per reactor volume (vvm). Results also showed that sparging CO₂ stripping, kLaCO2, is dominated by the gas throughput. As a result, a combination of a minimum constant vvm air or N₂ flow with a similar specific power was used as the general scale-up criterion. An equation was developed to determine the minimum vvm required for removing CO₂ produced from cell respiration. We demonstrated the effectiveness of using such scale-up criterion with five MAb projects exhibiting different cell growth and metabolic characteristics, scaled from 3 to 2,000 L bioreactors across four sites. © 2017 American Institute of Chemical Engineers Biotechnol. Prog., 33:1146-1159, 2017.

Effects of influent C/N ratios on CO2 and CH4 emissions from vertical subsurface flow constructed wetlands treating synthetic municipal wastewater

Greenhouse gases (GHG) emissions from constructed wetlands (CWs) can mitigate the environmental benefits of nutrient removal because reduced water pollution could be replaced by emission of GHG. Therefore, the GHG (CO(2) and CH(4)) fluxes of vertical subsurface flow constructed wetlands (VSSF CWs) under different influent C/N ratios of synthetic municipal wastewater were analyzed directly by GHG flux measurements, and estimated by carbon mass balance (CMB) over a 12 month period. The VSSF CWs system achieved the highest biological nutrient removal (BNR) efficiency between C/N ratios of 5:1 and 10:1 across all kinds of pollutants. Variation in influent C/N ratios dramatically influenced GHG fluxes from the VSSF CWs system. The GHG flux measured in situ agreed with those predicted by the CMB model and represented relatively low GHG fluxes when C/N ratios were between 2.5:1 and 5:1. It was determined that the optimum C/N ratio is 5:1, at which VSSF CWs can achieve a relatively high BNR efficiency and a low level of GHG flux.

Advanced control for photoautotrophic growth and CO2-utilization efficiency using a membrane carbonation photobioreactor (MCPBR)

A membrane carbonation (MC) module uses bubbleless gas-transfer membranes to supply inorganic carbon (C(i)) for photoautotrophic cyanobacterial growth in a photobioreactor (PBR); this creates the novel MCPBR system, which allows precise control of the CO(2)-delivery rate and minimal loss of CO(2) to the atmosphere. Experiments controlled the supply rate of C(i) to the main PBR by regulating the recirculation rate (Q(R)) between the module of MC chamber and the main PBR. The experiments evaluated how Q(R) controls the CO(2) mass transport in MC chamber and how it connects with the biomass production rate, C(i) concentration, pH in the PBR, and CO(2)-utilization efficiency. The biomass production rate and C(i) concentration increased in response to the C(i) supply rate (controlled by Q(R)), but not in linear proportion. The biomass production rate increased less than C(i) due to increased light limitation. Except for the highest Q(R), when the higher C(i) concentration caused the pH to decrease, CO(2) loss to gas ventilation was negligible. The results demonstrate that this MCPBR offers independent control over the growth of photoautotrophic biomass, pH control, and minimal loss of CO(2) to the atmosphere.

Development and calibration of bio-kinetic model for surfactant biodegradation with combined respirometric and titrimetric measurements

Substrate removal mechanism in aerobic activated sludge processes was lately modeled using the simultaneous storage and growth (SSAG) phenomenon. The SSAG model was further refined with titrimetric components and successfully calibrated using both respirometric and titrimetric measurements for common substrate acetate. However, the improved SSAG model calibration was not verified with other organic substrates. Furthermore, very few studies are available in the literature on surfactant bio-kinetics, which generally use off-line experimental measurements with limited model-based interpretation. Therefore, the aim of this paper is to demonstrate its applicability for surfactant biodegradation using on-line measurements. Batch experiments were conducted using sodium dodecyl sulfate (SDS) as a test surfactant. Model calibration was done successfully for three different SDS concentrations using respirometric, titrimetric and combined respirometric-titrimetric measurement approaches. The parameter estimation results from all three stated combinations were statistically evaluated and found to be very close validating the model.

Control of mineral scale deposition in cooling systems using secondary-treated municipal wastewater

Secondary-treated municipal wastewater (MWW) is a promising alternative to freshwater as power plant cooling system makeup water, especially in arid regions. A prominent challenge for the successful use of MWW for cooling is potentially severe mineral deposition (scaling) on pipe surfaces. In this study, theoretical, laboratory, and field work was conducted to evaluate the mineral deposition potential of MWW and its deposition control strategies under conditions relevant to power plant cooling systems. Polymaleic acid (PMA) was found to effectively reduce scale formation when the makeup water was concentrated four times in a recirculating cooling system. It was the most effective deposition inhibitor of those studied when applied at 10 mg/L dosing level in a synthetic MWW. However, the deposition inhibition by PMA was compromised by free chlorine added for biogrowth control. Ammonia present in the wastewater suppressed the reaction of the free chlorine with PMA through the formation of chloramines. Monochloramine, an alternative to free chlorine, was found to be less reactive with PMA than free chlorine. In pilot tests, scaling control was more challenging due to the occurrence of biofouling even with effective control of suspended bacteria. Phosphorous-based corrosion inhibitors are not appropriate due to their significant loss through precipitation reactions with calcium. Chemical equilibrium modeling helped with interpretation of mineral precipitation behavior but must be used with caution for recirculating cooling systems, especially with use of MWW, where kinetic limitations and complex water chemistries often prevail.

Using the rate of respiration to monitor events in the infection of Escherichia coli cultures by bacteriophage T4

The growing interest in applications of bacteriophages creates a need for improvements in the production processes. Continuous monitoring of the phage production is an essential aspect of any control strategy and, at present, there is no completely satisfactory option. The approach presented here uses IR-spectrometry to continuously measure the rate of respiration (CO(2) released) of Escherichia coli infected by phage T4 at various multiplicities of infection (MOI). Within the trends in these data, or in other aspects of the rate of respiration, it was possible to reliably and reproducibly identify five features that reflected specific events in the infection process. These included two events in the host cell apparent growth rate and events in the magnitude of the host cell density, in the measurement of OD(600) or in the specific rate of respiration. All of these correlations were within 95% confidence showing that they are suitable for the monitoring and control of E. coli populations infected by phage T4. This method is reliable, cheap, and can be operated in-line and in real time.

Monitoring off-gas O2/CO2 to predict nitrification performance in activated sludge processes

Nitrification/denitrification (NDN) processes are the most widely used technique to remove nitrogenous pollutants from municipal wastewater. The performance of nitrogen removal in the NDN process depends on the metabolism of nitrifying bacteria, and is dependent on adequate oxygen supply. Off-gas testing is a convenient and popular method for measuring oxygen transfer efficiency (OTE) under process conditions and can be performed in real-time. Since carbon dioxide is produced by carbonaceous oxidizing organism and not by nitrifiers, it should be possible to use the off-gas carbon dioxide mole fraction to estimate nitrification performance independently of the oxygen uptake rate (OUR) or OTE. This paper used off-gas data with a dynamic model to estimate nitrifying efficiency for various activated sludge process conditions. The relationship among nitrification, oxygen transfer, carbon dioxide production, and pH change was investigated. Experimental results of an online off-gas monitoring for a full-scale treatment plant were used to validate the model. The results showed measurable differences in OUR and carbon dioxide transfer rate (CTR) and the simulations successfully predicted the effluent ammonia by using the measured CO(2) and O(2) contents in off-gas as input signal. Carbon dioxide in the off-gas could be a useful technique to control aeration and to monitor nitrification rate.

Calibration of biokinetic model for acetate biodegradation using combined respirometric and titrimetric measurements

Simultaneous storage and growth model has recently gained increased acceptance among researchers that can better interpret the processes occurring in activated sludge processes during aerobic biodegradation of organic carbon. The model underwent further improvement and was successfully calibrated using respirometric measurements, acetate being a test substrate. However, model based interpretation of titrimetry needs to be verified for proper validation of this model since pH and dissolved oxygen dynamics occur simultaneously in a batch reactor. Hence, in this paper, it is aimed to modify the existing model by introducing stoichiometric parameters involved in titrimetry in each step of the growth and storage phases along with the consideration of non-linear carbon dioxide transfer rate in liquid phase. The model calibration was done for three different acetate concentrations using titrimetric, respirometric and combined respirometric-titrimetric measurements. The parameter estimation results from all three combinations were found to be very close that supports the validity of the model.

The use of oxygen uptake rate to monitor discovery of microbial and enzymatic biocatalysts

Arising from the requirement for discovery of novel biocatalysts with unusual properties, a process was developed which uniquely combines aspects of continuous culture with the measurement of oxygen uptake. This adaptation of the chemostat can be used to facilitate the isolation of a number of microorganisms with desirable properties, particularly those with useful metabolic capabilities and/or enzymes. The technique was also used to provide feedback on the metabolic status of a microbial population and increase the feed flow rate (i.e., dilution rate) thereby enabling the isolation of microorganisms with enhanced 1,3-propanediol dehydrogenase activity. The use of oxygen uptake as an indicator of cellular activity enables indirect measurement of substrate utilization and provides a real-time online assessment of the status of microbial enrichment or evolutionary processes and provides an opportunity, through the use of feedback systems, to control these processes. To demonstrate the utility of the technique, oxygen uptake rate (OUR) was compared with a range of conventional analytical techniques that are typically used to monitor enrichment/evolutionary processes and showed good correlation. Further validation was demonstrated by monitoring a characterizable microbial population shift using OUR. The population change was confirmed using off-line analytical techniques that are traditionally used to determine microbial activity. OUR was then used to monitor the enrichment of microorganisms capable of using a solvent (1-methyl-2-pyrrolidinone) as the sole source of carbon for energy and biomass formation from a heterogeneous microbial population. After purification the microorganisms taken from the enrichment process were able to completely utilize 1 g L(-1) 1-methyl-2-pyrrolidinone within 24 h demonstrating that the technique had correctly indicated the enriched population was capable of growth on 1-methyl-2-pyrrolidinone. The technique improves on conventional microbial enrichment that utilizes continuous culture by providing a real-time assessment of the enrichment process and the opportunity to use the OUR output for automated control and variation of one or more growth parameters.

Scale-up analysis for a CHO cell culture process in large-scale bioreactors

Bioprocess scale-up is a fundamental component of process development in the biotechnology industry. When scaling up a mammalian cell culture process, it is important to consider factors such as mixing time, oxygen transfer, and carbon dioxide removal. In this study, cell-free mixing studies were performed in production scale 5,000-L bioreactors to evaluate scale-up issues. Using the current bioreactor configuration, the 5,000-L bioreactor had a lower oxygen transfer coefficient, longer mixing time, and lower carbon dioxide removal rate than that was observed in bench scale 5- and 20-L bioreactors. The oxygen transfer threshold analysis indicates that the current 5,000-L configuration can only support a maximum viable cell density of 7 x 10(6) cells mL(-1). Moreover, experiments using a dual probe technique demonstrated that pH and dissolved oxygen gradients may exist in 5,000-L bioreactors using the current configuration. Empirical equations were developed to predict mixing time, oxygen transfer coefficient, and carbon dioxide removal rate under different mixing-related engineering parameters in the 5,000-L bioreactors. These equations indicate that increasing bottom air sparging rate is more efficient than increasing power input in improving oxygen transfer and carbon dioxide removal. Furthermore, as the liquid volume increases in a production bioreactor operated in fed-batch mode, bulk mixing becomes a challenge. The mixing studies suggest that the engineering parameters related to bulk mixing and carbon dioxide removal in the 5,000-L bioreactors may need optimizing to mitigate the risk of different performance upon process scale-up.

Extensions to modeling aerobic carbon degradation using combined respirometric-titrimetric measurements in view of activated sludge model calibration

Recently a model was introduced to interpret the respirometric (OUR) -titrimetric (Hp) data obtained from aerobic oxidation of different carbon sources in view of calibration of Activated Sludge Model No.1 (ASM1). The model requires, among others, the carbon dioxide transfer rate (CTR) to be relatively constant during aerobic experiments. As CTR is an inherently nonlinear process, this assumption may not hold for certain experimental conditions. Hence, we extended the model to describe the nonlinear CTR behavior. A simple calibration procedure of the CO2 model was developed only using titrimetric data. The identifiable parameter subset of this model when using titrimetric data only contained the first equilibrium constant of the CO2 dissociation, pK1, the initial aqueous CO2 concentration, C(Tinit) and the nitrogen content of biomass, i(NBM). The extended model was then successfully applied to interpret typical data obtained from respirometric-titrimetric measurements with a nonlinear CO2 stripping process. The parameter estimation results using titrimetric data were consistent with the results estimated using respirometric data (OUR) alone or combined OUR and Hp data, thereby supporting the validity of the dynamic CO2 model and its calibration approach. The increased range of applicability and accurate utilization of the titrimetric data are expected to contribute particularly to the improvement of calibration of ASM models using batch experiments.

Transient response of aerobic and anoxic activated sludge activities to sudden substrate concentration changes

The state-of-the-art understanding of activated sludge processes as summarized in activated sludge models (ASMs) predicts an instantaneous increase in the biomass activity (which is measured, e.g., by the corresponding respiration rate OUR, NUR, etc.) under sudden substrate concentration changes. Experimental data (e.g., short-term batch respiration experiments under aerobic or anoxic conditions) collected for the calibration of the dynamic models (ASMs) often exhibit a transient phenomenon while attaining maximum activity, which cannot be explained by the current understanding of the activated sludge process. That transient phenomenon exhibits itself immediately upon addition of a substrate source to an endogenously respiring activated sludge sample and it usually takes a few minutes until the activated sludge reaches its maximum possible rate under given environmental conditions. This discrepancy between the state-of-the-art model and the experimental data is addressed in detail in this investigation. It is shown that the discrepancy is not caused by an error in the experimental set-up/data but it is rather due to model inadequacy. Among the hypotheses proposed, it appears that this transient response of the activated sludge most likely results from the sequence of intracellular reactions involved in substrate degradation by the activated sludge. Results from studies performed elsewhere with pure cultures (S. cerevisae and E. coli) support the hypothesis. The transient phenomenon can be described by a dynamic metabolic network model or by a simple first-order model, as adopted in this study. The transient phenomenon occurring in short-term batch respiration experiments is shown to interfere severely with parameter estimation if not modeled properly (2.8%, 11.5%, and 16.8% relative errors [average of three experiments] on Y(H), micro(maxH), and K(S), respectively). Proper modeling of this transient phenomenon whose time constant is on the order of minutes (1 to 3 min) is expected to contribute fundamentally to a better understanding and modeling of Orbal, carousel, and SBR-type treatment plants with fast-alternating process conditions, although such studies are beyond the scope of this report.

Monitoring and control of anaerobic reactors

The current status in monitoring and control of anaerobic reactors is reviewed. The influence of reactor design and waste composition on the possible monitoring and control schemes is examined. After defining the overall control structure, and possible control objectives, the possible process measurements are reviewed in detail. In the sequel, possible manipulated variables, such as the hydraulic retention time, the organic loading rate, the sludge retention time, temperature, pH and alkalinity are evaluated with respect to the two main reactor types: high-rate and low-rate. Finally, the different control approaches that have been used are comprehensively described. These include simple and adaptive controllers, as well as more recent developments such as fuzzy controllers, knowledge-based controllers and controllers based on neural networks.

Development of a novel titration and off-gas analysis (TOGA) sensor for study of biological processes in wastewater treatment systems

The development of the new TOGA (titration and off-gas analysis) sensor for the detailed study of biological processes in wastewater treatment systems is outlined. The main innovation of the sensor is the amalgamation of titrimetric and off-gas measurement techniques. The resulting measured signals are: hydrogen ion production rate (HPR), oxygen transfer rate (OTR), nitrogen transfer rate (NTR), and carbon dioxide transfer rate (CTR). While OTR and NTR are applicable to aerobic and anoxic conditions, respectively, HPR and CTR are useful signals under all of the conditions found in biological wastewater treatment systems, namely, aerobic, anoxic and anaerobic. The sensor is therefore a powerful tool for studying the key biological processes under all these conditions. A major benefit from the integration of the titrimetric and off-gas analysis methods is that the acid/base buffering systems, in particular the bicarbonate system, are properly accounted for. Experimental data resulting from the TOGA sensor in aerobic, anoxic, and anaerobic conditions demonstrates the strength of the new sensor. In the aerobic environment, carbon oxidation (using acetate as an example carbon source) and nitrification are studied. Both the carbon and ammonia removal rates measured by the sensor compare very well with those obtained from off-line chemical analysis. Further, the aerobic acetate removal process is examined at a fundamental level using the metabolic pathway and stoichiometry established in the literature, whereby the rate of formation of storage products is identified. Under anoxic conditions, the denitrification process is monitored and, again, the measured rate of nitrogen gas transfer (NTR) matches well with the removal of the oxidised nitrogen compounds (measured chemically). In the anaerobic environment, the enhanced biological phosphorus process was investigated. In this case, the measured sensor signals (HPR and CTR) resulting from acetate uptake were used to determine the ratio of the rates of carbon dioxide production by competing groups of microorganisms, which consequently is a measure of the activity of these organisms. The sensor involves the use of expensive equipment such as a mass spectrometer and requires special gases to operate, thus incurring significant capital and operational costs. This makes the sensor more an advanced laboratory tool than an on-line sensor.

Dynamic calibration and dissolved gas analysis using membrane inlet mass spectrometry for the quantification of cell respiration

A membrane inlet mass spectrometer connected to a miniaturized reactor was applied for dynamic dissolved gas analysis. Cell samples were taken from 7 mL shake flask cultures of Corynebacterium glutamicum ATCC 13032, and transferred to the 12 mL miniaturized reactor. There, oxygen uptake and carbon dioxide and its mass isotopomer production rates were determined using a new experimental procedure and applying nonlinear model equations. A novel dynamic method for the calibration of the membrane inlet mass spectrometer using first-order dynamics was developed. To derive total dissolved concentration of all carbon dioxide species (C(T)) from dissolved carbon dioxide concentration ([CO(2)](aq)), the ratio of C(T) to [CO(2)](aq) was determined by nonlinear parameter estimation, whereas the mass transfer coefficient of CO(2) was determined by the Wilke-Chang correlation. Subsequently, the suitability of the model equations for respiration measurements was examined using residual analysis and the Jarque-Bera hypothesis test. The resulting residuals were found to be random with normal distribution, which proved the adequacy of the application of the model for cell respiration analysis. Hence, dynamic changes in respiration activities could be accurately analyzed using membrane inlet mass spectrometry with the novel calibration method.

Calorimetry: a tool for assessing microbial activity under aerobic and anoxic conditions

For many years, calorimetric measurements have been used for understanding, modelling, controlling, and optimising chemical reactions. Calorimetry could be as well utilised to investigate biological processes, which however, involve very small amount of heat and therefore require very sensitive instruments. For this purpose, a Mettler Toledo RCI (Reaction calorimeter) was modified, changing both hardware and software, increasing its resolution up to 5 10m W/l. Such sensitivity allows the monitoring of aerobic and anoxic processes. This paper points out the excellent agreement between calorimetric and respirometric data, obtained simultaneously under aerobic conditions using activated sludge from a lab-scale scale reactor. Heat production rate can be directly converted in oxygen uptake rate by means of a correlation factor, whose value is approximately the same for all aerobic respiratory metabolisms. Taking into account this factor, calorimetric data were introduced in a chemical oxygen demand based model and processed for the estimation of kinetic parameters of heterotrophic biomass. Aerobic heterotrophic, denitrifying, and autotrophic nitrifying activity were determined by specific calorimetric tests. The effect of potentially toxic or inhibitory substances on the activity of all microbial communities was as well pointed out in these measurements.

An automated test for measuring polymer biodegradation

The biodegradability of polymer materials as evaluated by the modified Sturm test is labor-intensive, cumbersome and costly and also tends to cumulate errors. An automated system for the measurement of carbon dioxide would overcome many of these disadvantages. We describe here a method in which CO2 was determined by IR spectroscopy. We compared the results with those from trapping CO2 in a solution of barium hydroxide (Ba(OH)2) followed by manual titration. The automated system was more reproducible, less costly and more compact. The automated system could also be employed to measure the biodegradability of other substances such as oils and detergents.

Considerations for osmolality measurement under elevated pCO(2): comparison of vapor pressure and freezing point osmometry

Osmolality increases with pCO(2) in bioreactors with pH control, and it has been shown that osmolality compensation by decreasing the basal NaCl concentration partially mitigates the adverse effects of elevated pCO(2) on animal cell growth, protein production, and glycosylation. Thus, measurement of osmolality is important for a complete characterization of the culture environment under elevated pCO(2). However, osmolality measurement may be compromised by CO(2) evolution. Freezing point depression and vapor pressure depression osmometry were directly compared for the measurement of osmolality in samples at elevated pCO(2) (up to 250 mmHg) and at a variety of pH values (6.7-7.5). More extensive degassing may be expected with the vapor pressure osmometer due to the smaller sample volume and larger surface area employed. However, both types of osmometer yielded similar results for all pCO(2) and pH values studied. Moreover, the measured values agreed with osmolality values calculated using a semi-empirical model. Further analysis showed that, while sample degassing may result in a large decrease in pCO(2), there is little associated decrease in osmolality. The great majority of total CO(2) in solution is present as bicarbonate (HCO(3)(-)). Although a small amount of HCO(3)(-) is converted to CO(2) to compensate for CO(2) evolution, further depletion of HCO(3)(-) is inhibited by the associated increase in medium pH and by the need for HCO(3)(-) to maintain charge neutrality in solution. This explanation is consistent with the observed similarity in osmolality values for the two types of osmometer. It was also observed that osmolality did not change in samples that were frozen at -20 degrees C for up to 1 year.

Bicarbonate concentration and osmolality are key determinants in the inhibition of CHO cell polysialylation under elevated pCO(2) or pH

Accumulation of CO(2) in animal cell cultures can be a significant problem during scale-up and production of recombinant glycoprotein biopharmaceuticals. By examining the cell-surface polysialic acid (PSA) content, we show that elevated CO(2) partial pressure (pCO(2)) can alter protein glycosylation. PSA is a high-molecular-weight polymer attached to several complex N-linked oligosaccharides on the neural cell adhesion molecule (NCAM), so that small changes in either core glycosylation or in polysialylation are amplified and easily measured. Flow-cytometric analysis revealed that PSA levels on Chinese hamster ovary (CHO) cells decrease with increasing pCO(2) in a dose-dependent manner, independent of any change in NCAM content. The results are highly pH-dependent, with a greater decrease in PSA at higher pH. By manipulating medium pH and pCO(2), we showed that decreases in PSA correlate well with bicarbonate concentration ([HCO(3)(-)]). In fact, it was possible to offset a 60% decrease in PSA content at 120 mm Hg pCO(2) by decreasing the pH from 7.3 to 6.9, such that [HCO(3)(-)] was lowered to that of control (38 mm Hg pCO(2)). When the increase in osmolality associated with elevated [HCO(3)(-)] was offset by decreasing the basal medium [NaCl], elevated [HCO(3)(-)] still caused a decrease in PSA, although less extensive than without osmolality control. By increasing [NaCl], we show that hyperosmolality alone decreases PSA content, but to a lesser extent than for the same osmolality increase due to elevated [NaHCO(3)]. In conclusion, we demonstrate the importance of pH and pCO(2) interactions, and show that [HCO(3)(-)] and osmolality can account for the observed changes in PSA content over a wide range of pH and pCO(2) values.

Indirect methods for characterization of carbon dioxide levels in fermentation broth

Various factors which influence dissolved carbon dioxide levels were indirectly evaluated in pilot scale and laboratory studies. For pilot scale studies, off-gas carbon dioxide (percentage in exit air) was measured using a mass spectrometer and then its potential impact on dissolved carbon dioxide concentrations qualitatively examined. Greater volumetric air flowrates reduced off-gas carbon dioxide levels more effectively at lower airflow ranges and thus lowered expected dissolved carbon dioxide levels through gas stripping. Lower broth pH values decreased off-gas carbon dioxide levels but increased expected dissolved carbon dioxide levels due to the pH-dependence of the gas/liquid carbon dioxide equilibrium. While back-pressure increases had an insignificant effect on off-gas carbon dioxide levels, they directly affected expected dissolved carbon dioxide levels according to Henry's law. Laboratory studies, conducted using both uninoculated and inoculated fermentation media, quantified the response of the media to pH changes with bicarbonate addition, specifically its buffering capacity. This effect then was related qualitatively to expected dissolved carbon dioxide levels. Higher dissolved carbon dioxide levels, as demonstrated by reduced pH changes with bicarbonate addition, thus would be expected for salt solutions of increased ionic strength and higher protein content media. In addition, pH changes with greater bicarbonate additions declined for fermentation samples taken over the course of a one week cultivation, most likely due to the higher protein content associated with biomass growth. The presence of weak acids/bases initially in the media or formed as metabolic by products, as well as the concentration of buffering ions such as phosphate, also were believed to be important contributing elements to the buffering capacity of the solution.