Oxygen transfer in hydrocarbon–aqueous dispersions and its applicability to alkane bioprocesses: A review

Developing an orbitally shaken bioreactor featuring a square vessel wall with a large circular chamfer

The impact of orbitally shaking bioreactors (OSRs) on the biopharmaceutical industry is becoming increasingly important. In the preliminary exploration of the orbitally shaking bioreactor performance, the vessel wall shape has a crucial influence on the mixing and mass transfer in the bioreactor. However, the shape of OSRs still maintains a cylindrical structure, significantly limiting the advantages of the orbital shaking mixing. Therefore, in order to further improve the mixing and mass transfer performance of OSRs, a novel wall shape is proposed in this paper. This novel wall shape consists of cylindrical and square parts and looks like a square tank with a large circular chamfer (STCC), which was found could effectively enhance the efficiency of material mixing and mass transfer theoretically. Based on the same specific volumetric power consumption, a comparative analysis was conducted on the mixing time and oxygen transfer efficiency of OSRs with different shape walls using simulation and experimental methods. The results showed that the OSR with STCC was expected to perform higher mixing and oxygen transfer efficiency than the OSR with cylindrical wall. These findings suggested a promising prospect for the future application of the OSRs with STCC.

The effect of Alcanivorax borkumensis SK2, a hydrocarbon-metabolising organism, on gas holdup in a 4-phase bubble column bioprocess

To design bioprocesses utilising hydrocarbon-metabolising organisms (HMO) as biocatalysts, the effect of the organism on the hydrodynamics of bubble column reactor (BCR), such as gas holdup, needs to be investigated. Therefore, this study investigates the first use of an HMO, Alcanivorax borkumensis SK2, as a solid phase in the operation and hydrodynamics of a BCR. The study investigated the gas holdup in 3-phase and 4-phase systems in a BCR under ranges of superficial gas velocities (U_G) from 1 to 3 cm/s, hydrocarbon (chain length C₁₃-₂₁) concentrations (H_C) of 0, 5, and 10% v/v and microbial concentrations (M_C) of 0, 0.35, 0.6 g/l. The results indicated that U_G was the most significant parameter, as gas holdup increases linearly with increasing U_G from 1 to 3 cm/s. Furthermore, the addition of hydrocarbons into the air-deionized water -SK2 system showed the highest increase in the gas holdup, particularly at high U_G (above 2 cm/s). The solids (yeast, cornflour, and SK2) phases had differing effects on gas holdup, potentially due to the difference in surface activity. In this work, SK2 addition caused a reduction in the fluid surface tension in the bioprocess which therefore resulted in an increase in the gas holdup in BCR. This work builds upon previous investigations in optimising the hydrodynamics for bubble column hydrocarbon bioprocesses for the application of alkane bioactivation.

Enhancement of triterpene production via in situ extractive fermentation of Sanghuangporus vaninii YC-1

There have been many studies on the activities and polysaccharide production of Sanghuangporus vaninii. However, few studies have looked at triterpene production from S. vaninii using liquid-state fermentation. A method for enhancing the production of triterpenes by in situ extractive fermentation (ISEF) was studied. Eight solvents were investigated as extractants for triterpene production in the ISEF system. The results showed that using vegetable oil as an extractant significantly increased the yield of total triterpenes and biomass of S. vaninii YC-1, reaching 18.98 ± 0.71 and 44.67 ± 2.21 g/L, respectively. In 5 L fermenter experiments, the added vegetable oil improved the dissolved oxygen condition of the fermentation broth and promoted the growth of S. vaninii YC-1. Furthermore, adding vegetable oil increased the expression of fatty acid synthesis-related genes such as FAD2 and SCD, thereby increasing the synthesis of unsaturated fatty acids in the cell membrane of S. vaninii YC-1. Therefore, the cell membrane permeability of S. vaninii YC-1 increased by 19%. Our results indicated that vegetable oil increased the permeability of S. vaninii YC-1 cell membranes to promote the production of total triterpenes. The use of vegetable oil as an extractant was thus effective in increasing the yield of triterpenes in the ISEF system.

Quantification of oxygen transfer coefficients in simulated hydrocarbon-based bioprocesses in a bubble column bioreactor

This study investigates the overall volumetric oxygen transfer coefficient (K_La) in multiphase hydrocarbon-based bioprocess under a range of hydrocarbon concentrations (H_C), solid loadings (deactivated yeast) (S_L) and superficial gas velocities (U_G) in a bubble column reactor (BCR). K_La increased with increasing U_G in the air-water system; due to an increase in the number of small bubbles which enhanced gas holdup. In air-water-yeast systems, the initial addition of yeast increased K_La significantly. Further increases in S_L reduced K_La, due to increases in the bubble size with increasing S_L. K_La decreased when H_C was added in air-water-hydrocarbon systems. However, U_G, S_L and H_C affected K_La differently in air-water-yeast-hydrocarbon systems: an indication of the complex interactions between the yeast and hydrocarbon phases which changed the system's hydrodynamics and therefore affected K_L. This work illustrates the effect of the operating conditions (S_L, H_C and U_G) on oxygen transfer behaviour in multiphase systems.

Effect of nanobubble application on performance and structural characteristics of microbial aggregates

Herein an investigation on the performance and structural properties with aspects of stability, composition, functional group, and three-dimensional distribution were approached to evaluate the influence of nanobubble aeration to the two most common microbial aggregates, activated sludge and biofilm. This study found that applying nanobubble effectively provided extra oxygen for microbial aggregates and achieved a 10.58% improvement in total nitrogen removal. The structure of microbial aggregates was enhanced, where extracellular protein and polysaccharides respectively increased as maximum as 3.40 and 1.70 times in biofilm and activated sludge, accompanied by the development of activated sludge floc size and the thickness of biofilm. Further investigation on extracellular polymeric substance and surface of microbial aggregates showed the composition of functional substances of microbial aggregates were shifted by the application of nanobubble, especially the oxygen-sensitive ones. Confocal laser scanning microscopy imaging visualized that the nanobubble changed the morphology of biofilm to a more evenly one. However, an adaptive process was more needed for activated sludge rather than biofilm, it suggested application of NB optimized the distribution of functional microorganisms in-depth and the metabolism pathway of them by accelerating the structure development of microbial aggregates, especially for biofilm.

Enhancing Chlorobenzene Biodegradation by Delftia tsuruhatensis Using a Water-Silicone Oil Biphasic System

In this study, a water-silicone oil biphasic system was developed to enhance the biodegradation of monochlorobenzene (CB) by Delftia tsuruhatensis LW26. Compared to the single phase, the biphasic system with a suitable silicone oil fraction (v/v) of 20% allowed a 2.5-fold increase in the maximum tolerated CB concentration. The CB inhibition on D. tsuruhatensis LW26 was reduced in the presence of silicone oil, and the electron transport system activity was maintained at high levels even under high CB stress. Adhesion of cells to the water-oil interface at the water side was observed using confocal laser scanning microscopy. Nearly 75% of cells accumulated on the interface, implying that another interfacial substrate uptake pathway prevailed besides that initiated by cells in the aqueous phase. The 8-fold increase in cell surface hydrophobicity upon the addition of 20% (v/v) silicone oil showed that silicone oil modified the surface characteristics of D. tsuruhatensis LW26. The protein/polysaccharide ratio of extracellular polymeric substances (EPS) from D. tsuruhatensis LW26 presented a 3-fold enhancement. These results suggested that silicone oil induced the increase in the protein content of EPS and rendered cells hydrophobic. The resulting hydrophobic cells could adhere on the water-oil interface, improving the mass transfer by direct CB uptake from silicone oil.

Mass Transfer in Multiphasic Gas/Liquid/Liquid Systems. KLa Determination Using the Effectiveness-Number of Transfer Unit Method

The Effectiveness-Number of Transfer Unit method (ε-NTU method) was applied to determine the overall mass transfer coefficient, KLa, of operating gas-liquid absorbers treating Volatile Organic Compounds (VOCs). This method requires the knowledge of the operating conditions (gas flow rate, QG; liquid flow rate, QL; scrubber volume V), the measurement of gaseous concentrations at the inlet, CGin, and at the outlet, CGout, of the contactor (in order to determine the effectiveness of the absorber ε) and the calculation of the Henry coefficient of the VOC between the gas and the liquid phases (HVOC). Coupled with the “equivalent absorption capacity” concept, the ε-NTU method was used to determine KLa of absorbers contacting a gas and a mixture of water and a Non Aqueous Phase, successfully. The method, validated from literature data for configurations countercurrent scrubbers and stirred tank reactors, could be used to simply determine the overall mass transfer coefficient of systems for which the standard KLa determination methods still remain non-reliable or inaccurate (viscous solvents, mixture of immiscible liquids, fermentation broths…).

Integrating multi-omics analyses of Nonomuraea dietziae to reveal the role of soybean oil in [(4'-OH)MeLeu]4-CsA overproduction

Background

Nonomuraea dietziae is a promising microorganism to mediate the region-specific monooxygenation reaction of cyclosporine A (CsA). The main product [(4′-OH)MeLeu]⁴-CsA possesses high anti-HIV/HCV and hair growth-stimulating activities while avoiding the immunosuppressive effect of CsA. However, the low conversion efficiency restricts the clinical application. In this study, the production of [(4′-OH)MeLeu]⁴-CsA was greatly improved by 55.6% from 182.8 to 284.4 mg/L when supplementing soybean oil into the production medium, which represented the highest production of [(4′-OH)MeLeu]⁴-CsA so far.

Results

To investigate the effect of soybean oil on CsA conversion, some other plant oils (corn oil and peanut oil) and the major hydrolysates of soybean oil were fed into the production medium, respectively. The results demonstrated that the plant oils, rather than the hydrolysates, could significantly improve the [(4′-OH)MeLeu]⁴-CsA production, suggesting that soybean oil might not play its role in the lipid metabolic pathway. To further unveil the mechanism of [(4′-OH)MeLeu]⁴-CsA overproduction under the soybean oil condition, a proteomic analysis based on the two-dimensional gel electrophoresis coupled with MALDI TOF/TOF mass spectrometry was implemented. The results showed that central carbon metabolism, genetic information processing and energy metabolism were significantly up-regulated under the soybean oil condition. Moreover, the gas chromatography-mass spectrometry-based metabolomic analysis indicated that soybean oil had a great effect on amino acid metabolism and tricarboxylic acid cycle. In addition, the transcription levels of cytochrome P450 hydroxylase (CYP) genes for CsA conversion were determined by RT-qPCR and the results showed that most of the CYP genes were up-regulated under the soybean oil condition.

Conclusions

These findings indicate that soybean oil could strengthen the primary metabolism and the CYP system to enhance the mycelium growth and the monooxygenation reaction, respectively, and it will be a guidance for the further metabolic engineering of this strain.

Electronic supplementary material

The online version of this article (doi:10.1186/s12934-017-0739-0) contains supplementary material, which is available to authorized users.

The influence of agitation on oil substrate dispersion and oxygen transfer in Pseudomonas aeruginosa USM-AR2 fermentation producing rhamnolipid in a stirred tank bioreactor

Water-immiscible substrate, diesel, was supplied as the main substrate in the fermentation of Pseudomonas aeruginosa USM-AR2 producing rhamnolipid biosurfactant, in a stirred tank bioreactor. In addition to the typical gas-aqueous system, this system includes gas-hydrocarbon-aqueous phases and the presence of surfactant (rhamnolipid) in the fermentation broth. The effect of diesel dispersion on volumetric oxygen transfer coefficient, k _L a, and thus oxygen transfer, was evaluated at different agitations of 400, 500 and 600 rpm. The oxygen transfer in this oil-water-surfactant system was shown to be affected by different oil dispersion at those agitation rates. The highest diesel dispersion was obtained at 500 rpm or impeller tip speed of 1.31 m/s, compared to 400 and 600 rpm, which led to the highest k _L a, growth and rhamnolipid production by P. aeruginosa USM-AR2. This showed the highest substrate mixing and homogenization at this agitation speed that led to the efficient substrate utilization by the cells. The oxygen uptake rate of P. aeruginosa USM-AR2 was 5.55 mmol/L/h, which showed that even the lowest k _L a (48.21 h^-1) and hence OTR (57.71 mmol/L/h) obtained at 400 rpm was sufficient to fulfill the oxygen demand of the cells. The effect of rhamnolipid concentration on k _L a showed that k _L a increased as rhamnolipid concentration increased to 0.6 g/L before reaching a plateau. This trend was similar for all agitation rates of 400, 500 and 600 rpm, which might be due to the increase in the resistance to oxygen transfer (k _L decrease) and the increase in the specific interfacial area (a).

Enhancement of oxygen mass transfer and gas holdup using palm oil in stirred tank bioreactors with xanthan solutions as simulated viscous fermentation broths

Volumetric mass transfer coefficient (k_La) is an important parameter in bioreactors handling viscous fermentations such as xanthan gum production, as it affects the reactor performance and productivity. Published literatures showed that adding an organic phase such as hydrocarbons or vegetable oil could increase the k_La. The present study opted for palm oil as the organic phase as it is plentiful in Malaysia. Experiments were carried out to study the effect of viscosity, gas holdup, and k_La on the xanthan solution with different palm oil fractions by varying the agitation rate and aeration rate in a 5 L bench-top bioreactor fitted with twin Rushton turbines. Results showed that 10% (v/v) of palm oil raised the k_La of xanthan solution by 1.5 to 3 folds with the highest k_La value of 84.44 h⁻¹. It was also found that palm oil increased the gas holdup and viscosity of the xanthan solution. The k_La values obtained as a function of power input, superficial gas velocity, and palm oil fraction were validated by two different empirical equations. Similarly, the gas holdup obtained as a function of power input and superficial gas velocity was validated by another empirical equation. All correlations were found to fit well with higher determination coefficients.

Influence of a Second Liquid Phase upon Carbon Dioxide Chemical Absorption

This work analyzes carbon dioxide mass transfer rate during chemical absorption from a gas phase to a liquid–liquid system based on an aqueous phase (glucosamine or pyrrolidine solutions) and an organic one. Two different kinds of silicone oil with different viscosity were used to perform the liquid phases, and it allows the analysis of the influence of this variable upon mass transfer rate. In these systems, a surfactant (Tween80) was added to stabilize the liquid–liquid system, and therefore, the influence of the presence of this surfactant in the liquid phase was studied. This substance produces a positive effect upon carbon dioxide absorption rate in glucosamine aqueous solutions, but the opposite effect was observed for the other amine employed in this work. Also, the influence caused by different operation variables, such as the gas flow-rate fed to the bubble contactor or the silicone oil concentration in the liquid phase, was studied.

Simultaneous biodegradation of volatile and toxic contaminant mixtures by solid-liquid two-phase partitioning bioreactors

Microbial inhibition and stripping of volatile compounds are two common problems encountered in the biotreatment of contaminated wastewaters. Both can be addressed by the addition of a hydrophobic auxiliary phase that can absorb and subsequently re-release the substrates, lowering their initial aqueous concentrations. Such systems have been described as Two Phase Partitioning Bioreactors (TPPBs). In the current work the performances of a solid-liquid TPPB, a liquid-liquid TPPB and a single phase reactor for the simultaneous degradation of butyl acetate (the volatile component) and phenol (the toxic component) have been compared. The auxiliary phase used in the solid-liquid TPPB was a 50:50 polymer mixture of styrene-butadiene rubber and Hytrel 8206, with high affinities for butyl acetate and phenol, respectively. The liquid-liquid TPPB employed silicone oil which has fixed physical properties, and had no capacity to absorb the toxic contaminant (phenol). Butyl acetate degradation was enhanced in both TPPBs relative to the single phase, arising from its sequestration into the auxiliary phase, thereby reducing volatilization losses. The solid-liquid TPPB additionally showed a substantial increase in the phenol degradation rate, relative to the silicone oil system, demonstrating the superiority and versatility of polymer based systems.

Oxygen mass transfer in a stirred tank bioreactor using different impeller configurations for environmental purposes

In this study, a miniature stirred tank bioreactor was designed for treatment of waste gas containing benzene, toluene and xylene. Oxygen mass transfer characteristics for various twin and single-impeller systems were investigated for 6 configurations in a vessel with 10 cm of inner diameter and working volume of 1.77L. Three types of impellers, namely, Rushton turbine, Pitched 4blades and Pitched 2blades impellers with downward pumping have been used. Deionized water was used as a liquid phase. With respect to other independent variables such as agitation speed, aeration rate, type of sparger, number of impellers, the relative performance of these impellers was assessed by comparing the values of (K_La) as a key parameter. Based on the experimental data, empirical correlations as a function of the operational conditions have been proposed, to study the oxygen transfer rates from air bubbles generated in the bioreactor. It was shown that twin Rushton turbine configuration demonstrates superior performance (23% to 77% enhancement in K_La) compared with other impeller compositions and that sparger type has negligible effect on oxygen mass transfer rate. Agitation speeds of 400 to 800 rpm were the most efficient speeds for oxygen mass transfer in the stirred bioreactor.

Oxygen Absorption into Stirred Emulsions of n-Alkanes

Absorption of pure oxygen into aqueous emulsions of n-heptane, n-dodecane, and n-hexadecane, respectively, has been studied at 0 to 100% oil volume fraction in a stirred tank at the stirring speed of 1000 min−1. The volumetric mass transfer coefficient, , was evaluated from the pressure decrease under isochoric and isothermal (298.2 K) conditions. The O/W emulsions of both n-dodecane and n-hexadecane show a maximum at 1-2% oil fraction as reported in several previous studies. Much stronger effects never reported before were observed at high oil fractions. Particularly, all n-heptane emulsions showed higher mass-transfer coefficients than both of the pure phases. The increase is by upto a factor of 38 as compared to pure water at 50% n-heptane. The effect is tentatively interpreted by oil spreading on the bubble surface enabled by a high spreading coefficient. In W/O emulsions of n-heptane and n-dodecane increases with the dispersed water volume fraction; the reason for this surprising trend is not clear.

Review of mass transfer aspects for biological gas treatment

This contribution reviews the mass transfer aspects of biotechnological processes for gas treatment, with an emphasis on the underlying principles and technical feasible methods for mass transfer enhancements. Understanding of the mass transfer behavior in bioreactors for gas treatment will result in improved reactor designs, reactor operation, and modeling tools, which are important to maximize efficiency and minimize costs. Various methods are discussed that show the potential for a more effective treatment of compounds with poor water solubility.

Ionic liquids: applications and future trends in bioreactor technology

Ionic liquids (ILs) constitute a new generation of solvents entirely composed of ions. ILs are usually considered as green solvents due to their negligible vapor pressure and other properties, such as non-flammability and high thermostability. Biotechnological applications involving the use of ILs are currently emerging. Reports on enzymatic and whole-cell catalysis in the presence of ILs increased from the past decade. Nonetheless, IL decomposition at relatively low temperatures as well as IL toxicity towards microbial cells and superior organisms recently challenge the "green label" commonly attached to ILs. On the other hand, the possibility to fine-tune practically all the IL physicochemical properties by modifying its chemical structure makes IL truly designer solvents. Thus, IL tuning can be applied to overcome toxicity drawbacks and to broaden their application spectrum. This work reviews the use of ILs in biotechnological applications. Finally, critical niches for future research are identified and discussed.

Bioreactor scale-up and oxygen transfer rate in microbial processes: an overview

In aerobic bioprocesses, oxygen is a key substrate; due to its low solubility in broths (aqueous solutions), a continuous supply is needed. The oxygen transfer rate (OTR) must be known, and if possible predicted to achieve an optimum design operation and scale-up of bioreactors. Many studies have been conducted to enhance the efficiency of oxygen transfer. The dissolved oxygen concentration in a suspension of aerobic microorganisms depends on the rate of oxygen transfer from the gas phase to the liquid, on the rate at which oxygen is transported into the cells (where it is consumed), and on the oxygen uptake rate (OUR) by the microorganism for growth, maintenance and production. The gas-liquid mass transfer in a bioprocess is strongly influenced by the hydrodynamic conditions in the bioreactors. These conditions are known to be a function of energy dissipation that depends on the operational conditions, the physicochemical properties of the culture, the geometrical parameters of the bioreactor and also on the presence of oxygen consuming cells. Stirred tank and bubble column (of various types) bioreactors are widely used in a large variety of bioprocesses (such as aerobic fermentation and biological wastewater treatments, among others). Stirred tanks bioreactors provide high values of mass and heat transfer rates and excellent mixing. In these systems, a high number of variables affect the mass transfer and mixing, but the most important among them are stirrer speed, type and number of stirrers and gas flow rate used. In bubble columns and airlifts, the low-shear environment compared to the stirred tanks has enabled successful cultivation of shear sensitive and filamentous cells. Oxygen transfer is often the rate-limiting step in the aerobic bioprocess due to the low solubility of oxygen in the medium. The correct measurement and/or prediction of the volumetric mass transfer coefficient, (k(L)a), is a crucial step in the design, operation and scale-up of bioreactors. The present work is aimed at the reviewing of the oxygen transfer rate (OTR) in bioprocesses to provide a better knowledge about the selection, design, scale-up and development of bioreactors. First, the most used measuring methods are revised; then the main empirical equations, including those using dimensionless numbers, are considered. The possible increasing on OTR due to the oxygen consumption by the cells is taken into account through the use of the biological enhancement factor. Theoretical predictions of both the volumetric mass transfer coefficient and the enhancement factor that have been recently proposed are described; finally, different criteria for bioreactor scale-up are considered in the light of the influence of OTR and OUR affecting the dissolved oxygen concentration in real bioprocess.