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Maureira D, Romero O, Illanes A, Wilson L, Ottone C. Industrial bioelectrochemistry for waste valorization: State of the art and challenges. Biotechnol Adv 2023; 64:108123. [PMID: 36868391 DOI: 10.1016/j.biotechadv.2023.108123] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/16/2022] [Revised: 02/24/2023] [Accepted: 02/26/2023] [Indexed: 03/05/2023]
Abstract
Bioelectrochemistry has gained importance in recent years for some of its applications on waste valorization, such as wastewater treatment and carbon dioxide conversion, among others. The aim of this review is to provide an updated overview of the applications of bioelectrochemical systems (BESs) for waste valorization in the industry, identifying current limitations and future perspectives of this technology. BESs are classified according to biorefinery concepts into three different categories: (i) waste to power, (ii) waste to fuel and (iii) waste to chemicals. The main issues related to the scalability of bioelectrochemical systems are discussed, such as electrode construction, the addition of redox mediators and the design parameters of the cells. Among the existing BESs, microbial fuel cells (MFCs) and microbial electrolysis cells (MECs) stand out as the more advanced technologies in terms of implementation and R&D investment. However, there has been little transfer of such achievements to enzymatic electrochemical systems. It is necessary that enzymatic systems learn from the knowledge reached with MFC and MEC to accelerate their development to achieve competitiveness in the short term.
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Affiliation(s)
- Diego Maureira
- School of Biochemical Engineering, Pontificia Universidad Católica de Valparaíso, Avenida Brasil 2085, Valparaíso, Chile
| | - Oscar Romero
- Bioprocess Engineering and Applied Biocatalysis Group, Departament of Chemical, Biological and Enviromental Engineering, Universitat Autònoma de Barcelona, 08193, Spain.
| | - Andrés Illanes
- School of Biochemical Engineering, Pontificia Universidad Católica de Valparaíso, Avenida Brasil 2085, Valparaíso, Chile
| | - Lorena Wilson
- School of Biochemical Engineering, Pontificia Universidad Católica de Valparaíso, Avenida Brasil 2085, Valparaíso, Chile
| | - Carminna Ottone
- School of Biochemical Engineering, Pontificia Universidad Católica de Valparaíso, Avenida Brasil 2085, Valparaíso, Chile.
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Weiland C, Steuwe E, Fitschen J, Hoffmann M, Schlüter M, Padberg-Gehle K, von Kameke A. Computational Study of Three-Dimensional Lagrangian Transport and Mixing in a Stirred Tank Reactor. CHEMICAL ENGINEERING JOURNAL ADVANCES 2023. [DOI: 10.1016/j.ceja.2023.100448] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/14/2023] Open
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Upscale fermenter design for lactic acid production from cheese whey permeate focusing on impeller selection and energy optimization. JOURNAL OF FOOD SCIENCE AND TECHNOLOGY 2022; 59:2263-2273. [PMID: 35602439 PMCID: PMC9114246 DOI: 10.1007/s13197-021-05239-6] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Revised: 08/03/2021] [Accepted: 08/10/2021] [Indexed: 11/26/2022]
Abstract
This study focusses on the design and scale-up of industrial lactic acid production by fermentation of dairy cheese whey permeate based on standard methodological parameters. The aim was to address the shortcomings of standard scale-up methodologies and provide a framework for fermenter scale-up that enables the accurate estimation of energy consumption by suitable selection of turbine and speed for industrial deployment. Moreover, life cycle assessment (LCA) was carried out to identify the potential impacts and possibilities to reduce the operation associated emissions at an early stage. The findings showed that a 3000 times scale-up strategy assuming constant geometric dimensions and specific energy consumption (P/Vw) resulted in lower impeller speed and energy demand. The Rushton turbine blade (RTB) and LightninA315 four-blade hydrofoil (LA315) were found to have the highest and lowest torque output, respectively, at a similar P/Vw of 2.8 kWm−3, with agitation speeds of 1.33 and 2.5 s−1, respectively. RTB demonstrating lower shear damage towards cells (up to 1.33 s−1) was selected because it permits high torque, low-power and acceptable turbulence. The LCA results showed a strong relation between the number of impellers installed and associated emissions suggesting a trade-off between mixing performance and environmental impacts.
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Matzke M, Behrens C, Jongebloed N, Steins D, Ulbricht M, Schultz HJ. Investigation and Visualization of Flow Fields in Stirred Tank Reactors Using a Fluorescence Tracer Method. CHEM-ING-TECH 2022. [DOI: 10.1002/cite.202200006] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Marian Matzke
- University of Applied Sciences Niederrhein Faculty of Chemistry Department of Chemical Engineering and Institute for Coatings and Surface Chemistry (ILOC) Adlerstraße 32 47798 Krefeld Germany
- University of Duisburg-Essen Chair of Technical Chemistry II Universitätsstraße 7 45141 Essen Germany
| | - Cheryl Behrens
- University of Applied Sciences Niederrhein Faculty of Chemistry Department of Chemical Engineering and Institute for Coatings and Surface Chemistry (ILOC) Adlerstraße 32 47798 Krefeld Germany
| | - Niklas Jongebloed
- University of Applied Sciences Niederrhein Faculty of Chemistry Department of Chemical Engineering and Institute for Coatings and Surface Chemistry (ILOC) Adlerstraße 32 47798 Krefeld Germany
| | - Dominik Steins
- University of Applied Sciences Niederrhein Faculty of Chemistry Department of Chemical Engineering and Institute for Coatings and Surface Chemistry (ILOC) Adlerstraße 32 47798 Krefeld Germany
| | - Mathias Ulbricht
- University of Duisburg-Essen Chair of Technical Chemistry II Universitätsstraße 7 45141 Essen Germany
| | - Heyko Jürgen Schultz
- University of Applied Sciences Niederrhein Faculty of Chemistry Department of Chemical Engineering and Institute for Coatings and Surface Chemistry (ILOC) Adlerstraße 32 47798 Krefeld Germany
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Gaugler L, Mast Y, Fitschen J, Hofmann S, Schlüter M, Takors R. Scaling-down biopharmaceutical production processes via a single multi-compartment bioreactor (SMCB). Eng Life Sci 2022; 23:e2100161. [PMID: 36619888 PMCID: PMC9815078 DOI: 10.1002/elsc.202100161] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/02/2021] [Revised: 02/09/2022] [Accepted: 02/18/2022] [Indexed: 01/11/2023] Open
Abstract
Biopharmaceutical production processes often use mammalian cells in bioreactors larger than 10,000 L, where gradients of shear stress, substrate, dissolved oxygen and carbon dioxide, and pH are likely to occur. As former tissue cells, producer cell lines such as Chinese hamster ovary (CHO) cells sensitively respond to these mixing heterogeneities, resulting in related scenarios being mimicked in scale-down reactors. However, commonly applied multi-compartment approaches comprising multiple reactors impose a biasing shear stress caused by pumping. The latter can be prevented using the single multi-compartment bioreactor (SMCB) presented here. The exchange area provided by a disc mounted between the upper and lower compartments in a stirred bioreactor was found to be an essential design parameter. Mimicking the mixing power input at a large scale on a small scale allowed the installation of similar mixing times in the SMCB. The particularities of the disc geometry may also be considered, finally leading to a converged decision tree. The work flow identifies a sharply contoured operational field comprising disc designs and power input to install the same mixing times on a large scale in the SMCB without the additional shear stress caused by pumping. The design principle holds true for both nongassed and gassed systems.
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Affiliation(s)
- Lena Gaugler
- Institute of Biochemical EngineeringUniversity of StuttgartStuttgartGermany
| | - Yannic Mast
- Institute of Biochemical EngineeringUniversity of StuttgartStuttgartGermany
| | - Jürgen Fitschen
- Institute of Multiphase FlowsHamburg University of TechnologyHamburgGermany
| | - Sebastian Hofmann
- Institute of Multiphase FlowsHamburg University of TechnologyHamburgGermany
| | - Michael Schlüter
- Institute of Multiphase FlowsHamburg University of TechnologyHamburgGermany
| | - Ralf Takors
- Institute of Biochemical EngineeringUniversity of StuttgartStuttgartGermany
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Dai YX, Wang ZH, Fan YW, Cheng ZQ. Analysis of mixing effect and power consumption of cone-bottom dual Rushton turbines stirred tank. CHEMICAL PAPERS 2022. [DOI: 10.1007/s11696-021-02010-1] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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Numerical analysis of hydrodynamics characteristics in a top-covered unbaffled stirred tank. CHEMICAL PAPERS 2021. [DOI: 10.1007/s11696-021-01767-9] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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Validation of Novel Lattice Boltzmann Large Eddy Simulations (LB LES) for Equipment Characterization in Biopharma. Processes (Basel) 2021. [DOI: 10.3390/pr9060950] [Citation(s) in RCA: 15] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/03/2023] Open
Abstract
Detailed process and equipment knowledge is crucial for the successful production of biopharmaceuticals. An essential part is the characterization of equipment for which Computational Fluid Dynamics (CFD) is an important tool. While the steady, Reynolds-averaged Navier–Stokes (RANS) k − ε approach has been extensively reviewed in the literature and may be used for fast equipment characterization in terms of power number determination, transient schemes have to be further investigated and validated to gain more detailed insights into flow patterns because they are the method of choice for mixing time simulations. Due to the availability of commercial solvers, such as M-Star CFD, Lattice Boltzmann simulations have recently become popular in the industry, as they are easy to set up and require relatively low computing power. However, extensive validation studies for transient Lattice Boltzmann Large Eddy Simulations (LB LES) are still missing. In this study, transient LB LES were applied to simulate a 3 L bioreactor system. The results were compared to novel 4D particle tracking (4D PTV) experiments, which resolve the motion of thousands of passive tracer particles on their journey through the bioreactor. Steady simulations for the determination of the power number followed a structured workflow, including grid studies and rotating reference frame volume studies, resulting in high prediction accuracy with less than 11% deviation, compared to experimental data. Likewise, deviations for the transient simulations were less than 10% after computational demand was reduced as a result of prior grid studies. The time averaged flow fields from LB LES were in good accordance with the novel 4D PTV data. Moreover, 4D PTV data enabled the validation of transient flow structures by analyzing Lagrangian particle trajectories. This enables a more detailed determination of mixing times and mass transfer as well as local exposure times of local velocity and shear stress peaks. For the purpose of standardization of common industry CFD models, steady RANS simulations for the 3 L vessel were included in this study as well.
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An overview of drive systems and sealing types in stirred bioreactors used in biotechnological processes. Appl Microbiol Biotechnol 2021; 105:2225-2242. [PMID: 33649923 PMCID: PMC7954712 DOI: 10.1007/s00253-021-11180-7] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/04/2020] [Revised: 02/05/2021] [Accepted: 02/14/2021] [Indexed: 12/27/2022]
Abstract
No matter the scale, stirred tank bioreactors are the most commonly used systems in biotechnological production processes. Single-use and reusable systems are supplied by several manufacturers. The type, size, and number of impellers used in these systems have a significant influence on the characteristics and designs of bioreactors. Depending on the desired application, classic shaft-driven systems, bearing-mounted drives, or stirring elements that levitate freely in the vessel may be employed. In systems with drive shafts, process hygiene requirements also affect the type of seal used. For sensitive processes with high hygienic requirements, magnetic-driven stirring systems, which have been the focus of much research in recent years, are recommended. This review provides the reader with an overview of the most common agitation and seal types implemented in stirred bioreactor systems, highlights their advantages and disadvantages, and explains their possible fields of application. Special attention is paid to the development of magnetically driven agitators, which are widely used in reusable systems and are also becoming more and more important in their single-use counterparts. Key Points • Basic design of the most frequently used bioreactor type: the stirred tank bioreactor • Differences in most common seal types in stirred systems and fields of application • Comprehensive overview of commercially available bioreactor seal types • Increased use of magnetically driven agitation systems in single-use bioreactors
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Abstract
The paper presents research on the phenomenon of an increase in mixing power during the emptying of a tank with two 6-PBT45° axial impellers in operation, located on a common shaft, pumping the liquid to the bottom of the mixing tank. A large increase in mixing power took place when the free surface of the liquid was just above the upper edge of one of the impellers (hp/D < 0.1). This increase was even more than 50% compared to the design power for a fully filled mixing vessel. Admittedly, high motor overload, while not very long, may damage it. The study investigated the instantaneous torques acting on the impeller shaft during the emptying of the tank and the velocity distributions in planes r-z. On their basis, the mechanism of the phenomenon observed was determined and correlation relationships were given that permitted the calculation of the numerical values of the power increase factors.
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Alagesan J, Jaisankar M, Muthuramalingam S, Mousset E, Chellam PV. Influence of number of azo bonds and mass transport limitations towards the elimination capacity of continuous electrochemical process for the removal of textile industrial dyes. CHEMOSPHERE 2021; 262:128381. [PMID: 33182108 DOI: 10.1016/j.chemosphere.2020.128381] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/21/2020] [Revised: 09/10/2020] [Accepted: 09/16/2020] [Indexed: 06/11/2023]
Abstract
This study focusses on the electrochemical decomposition of synthetic azo dyes (RO16, RR120 and DR80) using stainless steel electrodes, which is efficient, cost effective and industrially driven process. The experiments were carried out in a continuous electrochemical reactor and the effects of influencing parameters (initial concentration of dye, electrolyte concentration, pH) governing the process efficiency was studied. The interaction between the influencing parameters was investigated using Response Surface Methodology (RSM) and the regression value obtained for the generated model was above 0.9 for all the three dyes. The elimination capacity of electrochemical reactor was studied for the continuous removal of azo dyes with different ranges of concentration (100-400 mg L-1) and flow rate (0.1-0.5 L h-1). The maximum elimination capacity was obtained at a flow rate of 0.5 L h-1 for 300 mg L-1 of initial concentration of dye for RO16 and RR120 whereas it was 0.5 L h-1 for 400 mg L-1 of DR80. Further, a general dimensionless current density relation has been established for stirred tank reactor and allowed characterizing the relationship between kinetics and mass transport contributing to the overall reaction rate. The results quantitatively confirmed that the rate of electrochemical decolorization increased with the increasing initial dye concentration and flow rate due to the mass transport limitation. As newly established, the decolorization is also directly linked to the number of azo bonds.
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Affiliation(s)
- Jaanavee Alagesan
- Centre for Research, Department of Biotechnology, Kamaraj College of Engineering & Technology, Madurai, Tamilnadu, India
| | - MecghaSri Jaisankar
- Centre for Research, Department of Biotechnology, Kamaraj College of Engineering & Technology, Madurai, Tamilnadu, India
| | - Sindhu Muthuramalingam
- Centre for Research, Department of Biotechnology, Kamaraj College of Engineering & Technology, Madurai, Tamilnadu, India
| | - Emmanuel Mousset
- Laboratoire Réactions et Génie des Procédés, UMR CNRS 7274, Université de Lorraine, 1 Rue Grandville BP 20451, 54001, Nancy Cedex, France.
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Thomas B, Ohde D, Matthes S, Engelmann C, Bubenheim P, Terasaka K, Schlüter M, Liese A. Comparative investigation of fine bubble and macrobubble aeration on gas utility and biotransformation productivity. Biotechnol Bioeng 2020; 118:130-141. [PMID: 32886350 DOI: 10.1002/bit.27556] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/27/2020] [Revised: 08/06/2020] [Accepted: 08/30/2020] [Indexed: 01/02/2023]
Abstract
The sufficient provision of oxygen is mandatory for enzymatic oxidations in aqueous solution, however, in process optimization this still is a bottleneck that cannot be overcome with the established methods of macrobubble aeration. Providing higher mass transfer performance through microbubble aerators, inefficient aeration can be overcome or improved. Investigating the mass transport performance in a model protein solution, the microbubble aeration results in higher kL a values related to the applied airstream in comparison with macrobubble aeration. Comparing the aerators at identical kL a of 160 and 60 1/h, the microbubble aeration is resulting in 25 and 44 times enhanced gas utility compared with aeration with macrobubbles. To prove the feasibility of microbubbles in biocatalysis, the productivity of a glucose oxidase catalyzed biotransformation is compared with macrobubble aeration as well as the gas-saving potential. In contrast to the expectation that the same productivities are achieved at identically applied kL a, microbubble aeration increased the gluconic acid productivity by 32% and resulted in 41.6 times higher oxygen utilization. The observed advantages of microbubble aeration are based on the large volume-specific interfacial area combined with a prolonged residence time, which results in a high mass transfer performance, less enzyme deactivation by foam formation, and reduced gas consumption. This makes microbubble aerators favorable for application in biocatalysis.
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Affiliation(s)
- Benjamin Thomas
- Hamburg University of Technology, Institute of Technical Biocatalysis, Hamburg, Germany
| | - Daniel Ohde
- Hamburg University of Technology, Institute of Technical Biocatalysis, Hamburg, Germany
| | - Simon Matthes
- Hamburg University of Technology, Institute of Multiphase Flows, Hamburg, Germany
| | - Claudia Engelmann
- Hamburg University of Technology, Institute of Technical Biocatalysis, Hamburg, Germany
| | - Paul Bubenheim
- Hamburg University of Technology, Institute of Technical Biocatalysis, Hamburg, Germany
| | - Koichi Terasaka
- Department of Applied Chemistry, Keio University, Yokohama, Japan
| | - Michael Schlüter
- Hamburg University of Technology, Institute of Multiphase Flows, Hamburg, Germany
| | - Andreas Liese
- Hamburg University of Technology, Institute of Technical Biocatalysis, Hamburg, Germany
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