Studies on the scale-up of biomass production with Scenedesmus spp. in flat-plate gas-lift photobioreactors

Toward a modeling, optimization, and predictive control framework for fed-batch metabolic cybergenetics

Biotechnology offers many opportunities for the sustainable manufacturing of valuable products. The toolbox to optimize bioprocesses includes extracellular process elements such as the bioreactor design and mode of operation, medium formulation, culture conditions, feeding rates, and so on. However, these elements are frequently insufficient for achieving optimal process performance or precise product composition. One can use metabolic and genetic engineering methods for optimization at the intracellular level. Nevertheless, those are often of static nature, failing when applied to dynamic processes or if disturbances occur. Furthermore, many bioprocesses are optimized empirically and implemented with little-to-no feedback control to counteract disturbances. The concept of cybergenetics has opened new possibilities to optimize bioprocesses by enabling online modulation of the gene expression of metabolism-relevant proteins via external inputs (e.g., light intensity in optogenetics). Here, we fuse cybergenetics with model-based optimization and predictive control for optimizing dynamic bioprocesses. To do so, we propose to use dynamic constraint-based models that integrate the dynamics of metabolic reactions, resource allocation, and inducible gene expression. We formulate a model-based optimal control problem to find the optimal process inputs. Furthermore, we propose using model predictive control to address uncertainties via online feedback. We focus on fed-batch processes, where the substrate feeding rate is an additional optimization variable. As a simulation example, we show the optogenetic control of the ATPase enzyme complex for dynamic modulation of enforced ATP wasting to adjust product yield and productivity.

Lab-scale photobioreactor systems: principles, applications, and scalability

Phototrophic microorganisms that convert carbon dioxide are being explored for their capacity to solve different environmental issues and produce bioactive compounds for human therapeutics and as food additives. Full-scale phototrophic cultivation of microalgae and cyanobacteria can be done in open ponds or closed photobioreactor systems, which have a broad range of volumes. This review focuses on laboratory-scale photobioreactors and their different designs. Illuminated microtiter plates and microfluidic devices offer an option for automated high-throughput studies with microalgae. Illuminated shake flasks are used for simple uncontrolled batch studies. The application of illuminated bubble column reactors strongly emphasizes homogenous gas distribution, while illuminated flat plate bioreactors offer high and uniform light input. Illuminated stirred-tank bioreactors facilitate the application of very well-defined reaction conditions. Closed tubular photobioreactors as well as open photobioreactors like small-scale raceway ponds and thin-layer cascades are applied as scale-down models of the respective large-scale bioreactors. A few other less common designs such as illuminated plastic bags or aquarium tanks are also used mainly because of their relatively low cost, but up-scaling of these designs is challenging with additional light-driven issues. Finally, this review covers recommendations on the criteria for photobioreactor selection and operation while up-scaling of phototrophic bioprocesses with microalgae or cyanobacteria.

Process Engineering Aspects for the Microbial Conversion of C1 Gases

Industrially applied bioprocesses for the reduction of C1 gases (CO₂ and/or CO) are based in particular on (syn)gas fermentation with acetogenic bacteria and on photobioprocesses with microalgae. In each case, process engineering characteristics of the autotrophic microorganisms are specified and process engineering aspects for improving gas and electron supply are summarized before suitable bioreactor configurations are discussed for the production of organic products under given economic constraints. Additionally, requirements for the purity of C1 gases are summarized briefly. Finally, similarities and differences in microbial CO₂ valorization are depicted comparing gas fermentations with acetogenic bacteria and photobioprocesses with microalgae.

A validated strategy to design efficient fermentation-industrial processes: agave spirit production

An industrial process is profitable when its individual unit operations are efficient and thus, this work shows a guideline for designing efficient fermentation-industrial processes for agave distilled production based on a sequential approach of optimization, beginning in the laboratory and followed by the adjustment of the variable values using the evolutionary operation method for successful process scaling. The results at the laboratory showed that a starter inoculum containing a 5 × 10⁶ cells/mL mixture of Kluyveromyces marxianus, Clavispora lusitaniae, and Kluyveromyces marxianus var. drosophilarum strains in a bioreactor containing agave syrup with 120 g/L fermented sugar, processed at a constant temperature of 33 °C and 1.0 VVM aeration for 1.6 h, led to a fermented product with a 4.18% (v/v) alcohol content after 72 h of processing time. The scale-up process results showed that the best operating conditions at the pilot-plant level were a temperature of 35 °C and aeration at 1.0 VVM for 1.2 h, which led to a fermented product with a 4.22% (v/v) total alcohol content after 72 h of processing time. These represent similar performance values for both production processes, but each one worked with their specific values of process variables, which demonstrates that each level of production had its own specific values for process variables. The volatile compound analysis shows that both distilled products contained a similar profile of volatile components that provide fruity and ethereal aromatic notes pleasant to the palate. Therefore, the process design for agave spirit production at the semi-industrial level was successfully achieved.

Comparison of Galdieria growth and photosynthetic activity in different culture systems

In the last years, the acidothermophilic red microalga Galdieria sulphuraria has been increasingly studied for industrial applications such as wastewater treatment, recovery of rare earth elements, production of phycobilins. However, even now it is not possible an industrial cultivation of this organism because biotechnological research on G. sulphuraria and allied species is relatively recent and fragmented. Having in mind a possible scale-up for commercial applications, we have compared the growth and photosynthetic performance of G. sulphuraria in four suspended systems (Inclined bubble column, Decanter Laboratory Flask, Tubular Bioreactor, Ultra-flat plate bioreactor) and one immobilized system (Twin Layer Sytem). The results showed that G. sulphuraria had the highest growth, productivity and photosynthetic performance, when grown on the immobilized system, which also offers some economics advantages.

Outdoor microalgae cultivation in airlift photobioreactor at high irradiance and temperature conditions: effect of batch and fed-batch strategies, photoinhibition, and temperature stress

The microalgae Scenedesmus abundans cultivated in five identical airlift photobioreactors (PBRs) in batch and fed-batch modes at the outdoor tropical condition. The microalgae strain S. abundans was found to tolerate high temperature (35-45 °C) and high light intensity (770-1690 µmol m^- 2 s^- 1). The highest biomass productivities were 152.5-162.5 mg L^- 1 day^- 1 for fed-batch strategy. The biomass productivity was drastically reduced due to photoinhibition effect at a culture temperature of > 45 °C. The lipid compositions showed fatty acids mainly in the form of saturated and monounsaturated fatty acids (> 80%) in all PBRs with Cetane number more than 51. The fed-batch strategies efficiently produced higher biomass and lipid productivities at harsh outdoor conditions. Furthermore, the microalgae also accumulated omega-3 fatty acid (C18:3) up to 14% (w/w) of total fatty acid at given outdoor condition.