1
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Cao J, Tao S. Liquid-liquid reactions performed by cellular reactors. Nat Commun 2024; 15:5579. [PMID: 38961117 PMCID: PMC11222485 DOI: 10.1038/s41467-024-49953-z] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/17/2023] [Accepted: 06/26/2024] [Indexed: 07/05/2024] Open
Abstract
Liquid-liquid reactions play a significant role in organic synthesis. However, control of the phase interface between incompatible two-phase liquids remains challenging. Moreover, separating liquid acid, base and oxidants from the reactor takes a long time and high cost. To address these issues, we draw inspiration from the structure and function of cells in living organisms and develop a biomimetic 3D-printed cellular reactor. The cellular reactor houses an aqueous phase containing the catalyst or oxidant while immersed in the organic phase reactant. This setup controls the distribution of the phase interface within the organic phase and increases the interface area by 2.3 times. Notably, the cellular reactor and the aqueous phase are removed from the organic phase upon completing the reaction, eliminating additional separation steps and preventing direct contact between the reactor and acidic, alkaline, or oxidizing substances. Furthermore, the cellular reactor offers the advantages of digital design feasibility and cost-effective manufacturing.
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Affiliation(s)
- Jinzhe Cao
- School of Chemistry, Dalian University of Technology, 116024, Dalian, Liaoning, China
| | - Shengyang Tao
- School of Chemistry, Dalian University of Technology, 116024, Dalian, Liaoning, China.
- State Key Laboratory of Fine Chemicals, Dalian University of Technology, 116024, Dalian, Liaoning, China.
- Frontier Science Center for Smart Materials, Dalian University of Technology, 116024, Dalian, Liaoning, China.
- Dalian Key Laboratory of Intelligent Chemistry, Dalian University of Technology, Dalian, Liaoning, China.
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2
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Singh VK, Jiménez del Val I, Glassey J, Kavousi F. Integration Approaches to Model Bioreactor Hydrodynamics and Cellular Kinetics for Advancing Bioprocess Optimisation. Bioengineering (Basel) 2024; 11:546. [PMID: 38927782 PMCID: PMC11200465 DOI: 10.3390/bioengineering11060546] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/26/2024] [Revised: 05/17/2024] [Accepted: 05/24/2024] [Indexed: 06/28/2024] Open
Abstract
Large-scale bioprocesses are increasing globally to cater to the larger market demands for biological products. As fermenter volumes increase, the efficiency of mixing decreases, and environmental gradients become more pronounced compared to smaller scales. Consequently, the cells experience gradients in process parameters, which in turn affects the efficiency and profitability of the process. Computational fluid dynamics (CFD) simulations are being widely embraced for their ability to simulate bioprocess performance, facilitate bioprocess upscaling, downsizing, and process optimisation. Recently, CFD approaches have been integrated with dynamic Cell reaction kinetic (CRK) modelling to generate valuable information about the cellular response to fluctuating hydrodynamic parameters inside large production processes. Such coupled approaches have the potential to facilitate informed decision-making in intelligent biomanufacturing, aligning with the principles of "Industry 4.0" concerning digitalisation and automation. In this review, we discuss the benefits of utilising integrated CFD-CRK models and the different approaches to integrating CFD-based bioreactor hydrodynamic models with cellular kinetic models. We also highlight the suitability of different coupling approaches for bioprocess modelling in the purview of associated computational loads.
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Affiliation(s)
- Vishal Kumar Singh
- Process and Chemical Engineering, School of Engineering and Architecture, University College Cork, T12 K8AF Cork, Ireland;
| | - Ioscani Jiménez del Val
- School of Chemical & Bioprocess Engineering, University College Dublin, D04 V1W8 Dublin, Ireland;
| | - Jarka Glassey
- Process and Chemical Engineering, School of Engineering and Architecture, University College Cork, T12 K8AF Cork, Ireland;
- School of Engineering, Newcastle University, Newcastle upon Tyne NE1 7RU, UK
| | - Fatemeh Kavousi
- Process and Chemical Engineering, School of Engineering and Architecture, University College Cork, T12 K8AF Cork, Ireland;
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3
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Schrader M, Schrinner K, Polomsky L, Ivanov D, Kampen I, Schilde C, Krull R, Kwade A. Quantification and modeling of macroparticle-induced mechanical stress for varying shake flask cultivation conditions. Front Bioeng Biotechnol 2023; 11:1254136. [PMID: 37731767 PMCID: PMC10507416 DOI: 10.3389/fbioe.2023.1254136] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/06/2023] [Accepted: 08/08/2023] [Indexed: 09/22/2023] Open
Abstract
In biotechnological processes, filamentous microorganisms are known for their broad product spectrum and complex cellular morphology. Product formation and cellular morphology are often closely linked, requiring a well-defined level of mechanical stress to achieve high product concentrations. Macroparticles were added to shake flask cultures of the filamentous actinomycete Lentzea aerocolonigenes to find these optimal cultivation conditions. However, there is currently no model concept for the dependence of the strength and frequency of the bead-induced stress on the process parameters. Therefore, shake flask simulations were performed for combinations of bead size, bead concentration, bead density and shaking frequency. Contact analysis showed that the highest shear stresses were caused by bead-bottom contacts. Based on this, a newly generated characteristic parameter, the stress area ratio (SAR), was defined, which relates the bead wall shear and normal stresses to the total shear area. Comparison of the SAR with previous cultivation results revealed an optimum pattern for product concentration and mean product-to-biomass related yield coefficient. Thus, this model is a suitable tool for future optimization, comparison and scaling up of shear-sensitive microorganism cultivation. Finally, the simulation results were validated using high-speed recordings of the bead motion on the bottom of the shake flask.
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Affiliation(s)
- Marcel Schrader
- Institute for Particle Technology, Technische Universität Braunschweig, Braunschweig, Germany
- Center of Pharmaceutical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
| | - Kathrin Schrinner
- Center of Pharmaceutical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
- Institute of Biochemical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
| | - Laura Polomsky
- Institute for Particle Technology, Technische Universität Braunschweig, Braunschweig, Germany
- Center of Pharmaceutical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
| | - Dimitri Ivanov
- Institute for Particle Technology, Technische Universität Braunschweig, Braunschweig, Germany
- Center of Pharmaceutical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
| | - Ingo Kampen
- Institute for Particle Technology, Technische Universität Braunschweig, Braunschweig, Germany
- Center of Pharmaceutical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
| | - Carsten Schilde
- Institute for Particle Technology, Technische Universität Braunschweig, Braunschweig, Germany
- Center of Pharmaceutical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
| | - Rainer Krull
- Center of Pharmaceutical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
- Institute of Biochemical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
| | - Arno Kwade
- Institute for Particle Technology, Technische Universität Braunschweig, Braunschweig, Germany
- Center of Pharmaceutical Engineering, Technische Universität Braunschweig, Braunschweig, Germany
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4
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Wang X, Mohsin A, Sun Y, Li C, Zhuang Y, Wang G. From Spatial-Temporal Multiscale Modeling to Application: Bridging the Valley of Death in Industrial Biotechnology. Bioengineering (Basel) 2023; 10:744. [PMID: 37370675 DOI: 10.3390/bioengineering10060744] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/15/2023] [Revised: 06/13/2023] [Accepted: 06/19/2023] [Indexed: 06/29/2023] Open
Abstract
The Valley of Death confronts industrial biotechnology with a significant challenge to the commercialization of products. Fortunately, with the integration of computation, automation and artificial intelligence (AI) technology, the industrial biotechnology accelerates to cross the Valley of Death. The Fourth Industrial Revolution (Industry 4.0) has spurred advanced development of intelligent biomanufacturing, which has evolved the industrial structures in line with the worldwide trend. To achieve this, intelligent biomanufacturing can be structured into three main parts that comprise digitalization, modeling and intellectualization, with modeling forming a crucial link between the other two components. This paper provides an overview of mechanistic models, data-driven models and their applications in bioprocess development. We provide a detailed elaboration of the hybrid model and its applications in bioprocess engineering, including strain design, process control and optimization, as well as bioreactor scale-up. Finally, the challenges and opportunities of biomanufacturing towards Industry 4.0 are also discussed.
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Affiliation(s)
- Xueting Wang
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai 200237, China
| | - Ali Mohsin
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai 200237, China
| | - Yifei Sun
- Key Laboratory of Smart Manufacturing in Energy Chemical Process, Ministry of Education, East China University of Science and Technology (ECUST), Shanghai 200237, China
| | - Chao Li
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai 200237, China
| | - Yingping Zhuang
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai 200237, China
| | - Guan Wang
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai 200237, China
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5
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Kheirkhah T, Neubauer P, Junne S. Controlling Aspergillus niger morphology in a low shear-force environment in a rocking-motion bioreactor. Biochem Eng J 2023. [DOI: 10.1016/j.bej.2023.108905] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/30/2023]
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6
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Vidya Muthulakshmi M, Srinivasan A, Srivastava S. Antioxidant Green Factories: Toward Sustainable Production of Vitamin E in Plant In Vitro Cultures. ACS OMEGA 2023; 8:3586-3605. [PMID: 36743063 PMCID: PMC9893489 DOI: 10.1021/acsomega.2c05819] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/07/2022] [Accepted: 12/14/2022] [Indexed: 06/18/2023]
Abstract
Vitamin E is a dietary supplement synthesized only by photosynthetic organisms and, hence, is an essential vitamin for human well-being. Because of the ever-increasing demand for natural vitamin E and limitations in existing synthesis modes, attempts to improve its yield using plant in vitro cultures have gained traction in recent years. With inflating industrial production costs, integrative approaches to conventional bioprocess optimization is the need of the hour for multifold vitamin E productivity enhancement. In this review, we briefly discuss the structure, isomers, and important metabolic routes of biosynthesis for vitamin E in plants. We then emphasize its vital role in human health and its industrial applications and highlight the market demand and supply. We illustrate the advantages of in vitro plant cell/tissue culture cultivation as an alternative to current commercial production platforms for natural vitamin E. We touch upon the conventional vitamin E metabolic pathway engineering strategies, such as single/multigene overexpression and chloroplast engineering. We highlight the recent progress in plant systems biology to rationally identify metabolic bottlenecks and knockout targets in the vitamin E biosynthetic pathway. We then discuss bioprocess optimization strategies for sustainable vitamin E production, including media/process optimization, precursor/elicitor addition, and scale-up to bioreactors. We culminate the review with a short discussion on kinetic modeling to predict vitamin E production in plant cell cultures and suggestions on sustainable green extraction methods of vitamin E for reduced environmental impact. This review will be of interest to a wider research fraternity, including those from industry and academia working in the field of plant cell biology, plant biotechnology, and bioprocess engineering for phytochemical enhancement.
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Affiliation(s)
- M. Vidya Muthulakshmi
- Department
of Biotechnology, Bhupat & Jyoti Mehta School of Biosciences, Indian Institute of Technology Madras (IIT Madras), Chennai, 600 036 Tamil Nadu, India
| | - Aparajitha Srinivasan
- Department
of Biotechnology, Bhupat & Jyoti Mehta School of Biosciences, Indian Institute of Technology Madras (IIT Madras), Chennai, 600 036 Tamil Nadu, India
| | - Smita Srivastava
- Department
of Biotechnology, Bhupat & Jyoti Mehta School of Biosciences, Indian Institute of Technology Madras (IIT Madras), Chennai, 600 036 Tamil Nadu, India
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7
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Blöbaum L, Haringa C, Grünberger A. Microbial lifelines in bioprocesses: From concept to application. Biotechnol Adv 2023; 62:108071. [PMID: 36464144 DOI: 10.1016/j.biotechadv.2022.108071] [Citation(s) in RCA: 6] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/21/2022] [Revised: 11/24/2022] [Accepted: 11/25/2022] [Indexed: 12/03/2022]
Abstract
Bioprocesses are scaled up for the production of large product quantities. With larger fermenter volumes, mixing becomes increasingly inefficient and environmental gradients get more prominent than in smaller scales. Environmental gradients have an impact on the microorganism's metabolism, which makes the prediction of large-scale performance difficult and can lead to scale-up failure. A promising approach for improved understanding and estimation of dynamics of microbial populations in large-scale bioprocesses is the analysis of microbial lifelines. The lifeline of a microbe in a bioprocess is the experience of environmental gradients from a cell's perspective, which can be described as a time series of position, environment and intracellular condition. Currently, lifelines are predominantly determined using models with computational fluid dynamics, but new technical developments in flow-following sensor particles and microfluidic single-cell cultivation open the door to a more interdisciplinary concept. We critically review the current concepts and challenges in lifeline determination and application of lifeline analysis, as well as strategies for the integration of these techniques into bioprocess development. Lifelines can contribute to a successful scale-up by guiding scale-down experiments and identifying strain engineering targets or bioreactor optimisations.
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Affiliation(s)
- Luisa Blöbaum
- Multiscale Bioengineering, Technical Faculty, Bielefeld University, Bielefeld, Germany; CeBiTec, Bielefeld University, Bielefeld, Germany
| | - Cees Haringa
- Bioprocess Engineering, Applied Sciences/Biotechnology, TU, Delft, Netherlands
| | - Alexander Grünberger
- Multiscale Bioengineering, Technical Faculty, Bielefeld University, Bielefeld, Germany; CeBiTec, Bielefeld University, Bielefeld, Germany; Microsystems in Bioprocess Engineering, Institute of Process Engineering in Life Sciences, Karlsruhe Institute of Technology, Karlsruhe, Germany.
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8
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Guo P, Tao S. Chirality enhanced shear‐free mixing of highly viscous fluids in an origami reactor. AIChE J 2022. [DOI: 10.1002/aic.18002] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/23/2022]
Affiliation(s)
- Pengfei Guo
- State Key Laboratory of Fine Chemicals, Frontier Science Center for Smart Materials, School of Chemical Engineering Dalian University of Technology Dalian China
- Department of Chemistry, School of Chemical Engineering Dalian University of Technology Dalian Liaoning China
| | - Shengyang Tao
- State Key Laboratory of Fine Chemicals, Frontier Science Center for Smart Materials, School of Chemical Engineering Dalian University of Technology Dalian China
- Department of Chemistry, School of Chemical Engineering Dalian University of Technology Dalian Liaoning China
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9
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Seidel S, Maschke RW, Kraume M, Eibl R, Eibl D. CFD modelling of a wave-mixed bioreactor with complex geometry and two degrees of freedom motion. FRONTIERS IN CHEMICAL ENGINEERING 2022. [DOI: 10.3389/fceng.2022.1021416] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022] Open
Abstract
Optimizing bioprocesses requires an in-depth understanding, from a bioengineering perspective, of the cultivation systems used. A bioengineering characterization is typically performed via experimental or numerical methods, which are particularly well-established for stirred bioreactors. For unstirred, non-rigid systems such as wave-mixed bioreactors, numerical methods prove to be problematic, as often only simplified geometries and motions can be assumed. In this work, a general approach for the numerical characterization of non-stirred cultivation systems is demonstrated using the CELL-tainer bioreactor with two degree of freedom motion as an example. In a first step, the motion is recorded via motion capturing, and a 3D model of the culture bag geometry is generated via 3D-scanning. Subsequently, the bioreactor is characterized with respect to mixing time, and oxygen transfer rate, as well as specific power input and temporal Kolmogorov length scale distribution. The results demonstrate that the CELL-tainer with two degrees of freedom outperforms classic wave-mixed bioreactors in terms of oxygen transport. In addition, it was shown that in the cell culture version of the CELL-tainer, the critical Kolmogorov length is not surpassed in any simulation.
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10
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Du YH, Wang MY, Yang LH, Tong LL, Guo DS, Ji XJ. Optimization and Scale-Up of Fermentation Processes Driven by Models. Bioengineering (Basel) 2022; 9:bioengineering9090473. [PMID: 36135019 PMCID: PMC9495923 DOI: 10.3390/bioengineering9090473] [Citation(s) in RCA: 6] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/05/2022] [Revised: 09/05/2022] [Accepted: 09/09/2022] [Indexed: 11/16/2022] Open
Abstract
In the era of sustainable development, the use of cell factories to produce various compounds by fermentation has attracted extensive attention; however, industrial fermentation requires not only efficient production strains, but also suitable extracellular conditions and medium components, as well as scaling-up. In this regard, the use of biological models has received much attention, and this review will provide guidance for the rapid selection of biological models. This paper first introduces two mechanistic modeling methods, kinetic modeling and constraint-based modeling (CBM), and generalizes their applications in practice. Next, we review data-driven modeling based on machine learning (ML), and highlight the application scope of different learning algorithms. The combined use of ML and CBM for constructing hybrid models is further discussed. At the end, we also discuss the recent strategies for predicting bioreactor scale-up and culture behavior through a combination of biological models and computational fluid dynamics (CFD) models.
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Affiliation(s)
- Yuan-Hang Du
- School of Food Science and Pharmaceutical Engineering, Nanjing Normal University, Nanjing 210023, China
| | - Min-Yu Wang
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Biotechnology and Pharmaceutical Engineering, Nanjing Tech University, Nanjing 211816, China
| | - Lin-Hui Yang
- School of Food Science and Pharmaceutical Engineering, Nanjing Normal University, Nanjing 210023, China
| | - Ling-Ling Tong
- School of Food Science and Pharmaceutical Engineering, Nanjing Normal University, Nanjing 210023, China
| | - Dong-Sheng Guo
- School of Food Science and Pharmaceutical Engineering, Nanjing Normal University, Nanjing 210023, China
- Correspondence: (D.-S.G.); (X.-J.J.)
| | - Xiao-Jun Ji
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Biotechnology and Pharmaceutical Engineering, Nanjing Tech University, Nanjing 211816, China
- Correspondence: (D.-S.G.); (X.-J.J.)
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11
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Mirzabe AH, Hajiahmad A, Fadavi A, Rafiee S. Temporary immersion systems (TISs): A comprehensive review. J Biotechnol 2022; 357:56-83. [PMID: 35973641 DOI: 10.1016/j.jbiotec.2022.08.003] [Citation(s) in RCA: 17] [Impact Index Per Article: 8.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/16/2022] [Revised: 08/02/2022] [Accepted: 08/05/2022] [Indexed: 11/27/2022]
Abstract
The temporary immersion systems (TISs) have been widely used in plant biotechnology. TISs have different advantages from the point of micropropagation and production of secondary metabolites over other continuous liquid-phase bioreactors. The current work presents the structure, operation mode, configuration type, and micropropagation or secondary metabolite production in TISs. This review deals with the advantages and disadvantages of TISs and the factors affecting their performance. Future research could focus on new designs based on CFD simulation, facilitating sterilization, and combining TISs with other bioreactors (e.g., mist bioreactors) to make a hybrid bioreactor.
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Affiliation(s)
- Amir Hossein Mirzabe
- Department of Mechanics of Biosystem Engineering, Faculty of Engineering & Technology, College of Agriculture & Natural Resources, University of Tehran, Karaj, Alborz, Iran.
| | - Ali Hajiahmad
- Department of Mechanics of Biosystem Engineering, Faculty of Engineering & Technology, College of Agriculture & Natural Resources, University of Tehran, Karaj, Alborz, Iran.
| | - Ali Fadavi
- Department of Food Technology, College of Aburaihan, University of Tehran, Tehran, Iran.
| | - Shahin Rafiee
- Department of Mechanics of Biosystem Engineering, Faculty of Engineering & Technology, College of Agriculture & Natural Resources, University of Tehran, Karaj, Alborz, Iran.
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12
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Hartmann FSF, Udugama IA, Seibold GM, Sugiyama H, Gernaey KV. Digital models in biotechnology: Towards multi-scale integration and implementation. Biotechnol Adv 2022; 60:108015. [PMID: 35781047 DOI: 10.1016/j.biotechadv.2022.108015] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/14/2022] [Revised: 06/03/2022] [Accepted: 06/27/2022] [Indexed: 12/28/2022]
Abstract
Industrial biotechnology encompasses a large area of multi-scale and multi-disciplinary research activities. With the recent megatrend of digitalization sweeping across all industries, there is an increased focus in the biotechnology industry on developing, integrating and applying digital models to improve all aspects of industrial biotechnology. Given the rapid development of this field, we systematically classify the state-of-art modelling concepts applied at different scales in industrial biotechnology and critically discuss their current usage, advantages and limitations. Further, we critically analyzed current strategies to couple cell models with computational fluid dynamics to study the performance of industrial microorganisms in large-scale bioprocesses, which is of crucial importance for the bio-based production industries. One of the most challenging aspects in this context is gathering intracellular data under industrially relevant conditions. Towards comprehensive models, we discuss how different scale-down concepts combined with appropriate analytical tools can capture intracellular states of single cells. We finally illustrated how the efforts could be used to develop digitals models suitable for both cell factory design and process optimization at industrial scales in the future.
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Affiliation(s)
- Fabian S F Hartmann
- Department of Biotechnology and Biomedicine, Technical University of Denmark, Søltofts Plads, Building 223, 2800 Kgs. Lyngby, Denmark
| | - Isuru A Udugama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan; Department of Chemical and Biochemical Engineering, Technical University of Denmark, Søltofts Plads, Building 228 A, 2800 Kgs. Lyngby, Denmark.
| | - Gerd M Seibold
- Department of Biotechnology and Biomedicine, Technical University of Denmark, Søltofts Plads, Building 223, 2800 Kgs. Lyngby, Denmark
| | - Hirokazu Sugiyama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan
| | - Krist V Gernaey
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Søltofts Plads, Building 228 A, 2800 Kgs. Lyngby, Denmark.
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13
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Zhang W, Zhao F, Li Y, Lou X, Dai C, Lv W, Qu X, Zheng S, Chen B, Galaev IY, Yun J. Suspension and transformation performance of poly(2-hydroxyethyl methacrylate)-based anion exchange cryogel beads with immobilized Lactobacillus paracasei cells as biocatalysts towards biosynthesis of phenyllactic acid in stirred tank bioreactors. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2021.12.010] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
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14
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Wang H, Duan X, Feng X, Mao ZS, Yang C. Effect of impeller type and scale-up on spatial distribution of shear rate in a stirred tank. Chin J Chem Eng 2022. [DOI: 10.1016/j.cjche.2021.03.004] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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15
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Esperança MN, Buffo MM, Mendes CE, Rodriguez GY, Béttega R, Badino AC, Cerri MO. Linking maximal shear rate and energy dissipation/circulation function in airlift bioreactors. Biochem Eng J 2022. [DOI: 10.1016/j.bej.2021.108308] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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16
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Shen B, Zhan X, He Y, Sun Z, Long J, Yang Y, Li X. Computational fluid dynamic analysis of mass transfer and hydrodynamics in a planetary centrifugal bioreactor. KOREAN J CHEM ENG 2021. [DOI: 10.1007/s11814-021-0817-1] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/19/2022]
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17
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Čelan A, Ćosić M, Penga Ž, Kuzmanić N. Connection of Hydrodynamics and Nucleation Kinetics in Dual‐Impeller Crystallizers. Chem Eng Technol 2021. [DOI: 10.1002/ceat.202000515] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
Affiliation(s)
- Antonija Čelan
- University of Split Faculty of Chemistry and Technology R. Boskovica 35 21 000 Split Croatia
| | - Marija Ćosić
- University of Split Faculty of Chemistry and Technology R. Boskovica 35 21 000 Split Croatia
| | - Željko Penga
- University of Split Faculty of Electrical Engineering Mechanical Engineering and Naval Architecture R. Boskovica 32 21 000 Split Croatia
| | - Nenad Kuzmanić
- University of Split Faculty of Chemistry and Technology R. Boskovica 35 21 000 Split Croatia
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18
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Nogueira DE, Cabral JM, Rodrigues CA. Single-Use Bioreactors for Human Pluripotent and Adult Stem Cells: Towards Regenerative Medicine Applications. Bioengineering (Basel) 2021; 8:68. [PMID: 34067549 PMCID: PMC8156863 DOI: 10.3390/bioengineering8050068] [Citation(s) in RCA: 10] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2021] [Revised: 05/10/2021] [Accepted: 05/12/2021] [Indexed: 12/15/2022] Open
Abstract
Research on human stem cells, such as pluripotent stem cells and mesenchymal stromal cells, has shown much promise in their use for regenerative medicine approaches. However, their use in patients requires large-scale expansion systems while maintaining the quality of the cells. Due to their characteristics, bioreactors have been regarded as ideal platforms to harbour stem cell biomanufacturing at a large scale. Specifically, single-use bioreactors have been recommended by regulatory agencies due to reducing the risk of product contamination, and many different systems have already been developed. This review describes single-use bioreactor platforms which have been used for human stem cell expansion and differentiation, along with their comparison with reusable systems in the development of a stem cell bioprocess for clinical applications.
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Affiliation(s)
- Diogo E.S. Nogueira
- Department of Bioengineering and iBB—Institute for Bioengineering and Biosciences, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal; (D.E.S.N.); (J.M.S.C.)
- Associate Laboratory i4HB—Institute for Health and Bioeconomy, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
| | - Joaquim M.S. Cabral
- Department of Bioengineering and iBB—Institute for Bioengineering and Biosciences, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal; (D.E.S.N.); (J.M.S.C.)
- Associate Laboratory i4HB—Institute for Health and Bioeconomy, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
| | - Carlos A.V. Rodrigues
- Department of Bioengineering and iBB—Institute for Bioengineering and Biosciences, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal; (D.E.S.N.); (J.M.S.C.)
- Associate Laboratory i4HB—Institute for Health and Bioeconomy, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
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Euler-Lagrangian Simulations: A Proper Tool for Predicting Cellular Performance in Industrial Scale Bioreactors. ADVANCES IN BIOCHEMICAL ENGINEERING/BIOTECHNOLOGY 2021. [PMID: 32978650 DOI: 10.1007/10_2020_133] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register]
Abstract
Eulerian-Lagrangian approach to investigate cellular responses in a bioreactor has become the center of attention in recent years. It was introduced to biotechnological processes about two decades ago, but within the last few years, it proved itself as a powerful tool to address scale-up and -down topics of bioprocesses. It can capture the history of a cell and reveal invaluable information for, not only, bioprocess control and design but also strain engineering. This way it will be possible to shed light on the actual environment that cell experiences throughout its lifespan. Lifelines of a microorganism in a bioreactor can serve as the missing link that encompasses the biological timescales and the physical timescales. For this purpose digitalization of bioreactors provides us with new insights that are not achievable in industrial reactors easily if at all, namely, substrate and product gradients; high-shear regions are among the most interesting factors that can be reproduced adequately with help of a digital twin. In this chapter basic principles of this method will be introduced, and later on some practical aspects of particle tracking technique will be illustrated. In the final section, some of the advantages and challenges associated with this method will be discussed.
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Two-fluids RANS predictions of gas cavities, power consumption, mixing time and oxygen transfer rate in an aerated fermenter scale-down stirred with multiple impellers. Biochem Eng J 2021. [DOI: 10.1016/j.bej.2020.107867] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/27/2022]
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21
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Xia J, Wang G, Fan M, Chen M, Wang Z, Zhuang Y. Understanding the scale-up of fermentation processes from the viewpoint of the flow field in bioreactors and the physiological response of strains. Chin J Chem Eng 2021. [DOI: 10.1016/j.cjche.2020.12.004] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/01/2023]
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22
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Buffo MM, Esperança MN, Farinas CS, Badino AC. Relation between pellet fragmentation kinetics and cellulolytic enzymes production by Aspergillus niger in conventional bioreactor with different impellers. Enzyme Microb Technol 2020; 139:109587. [DOI: 10.1016/j.enzmictec.2020.109587] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/28/2020] [Revised: 04/07/2020] [Accepted: 04/24/2020] [Indexed: 10/24/2022]
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Wang G, Haringa C, Noorman H, Chu J, Zhuang Y. Developing a Computational Framework To Advance Bioprocess Scale-Up. Trends Biotechnol 2020; 38:846-856. [DOI: 10.1016/j.tibtech.2020.01.009] [Citation(s) in RCA: 25] [Impact Index Per Article: 6.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/21/2019] [Revised: 01/27/2020] [Accepted: 01/29/2020] [Indexed: 01/10/2023]
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24
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Wang Z, Xue J, Sun H, Zhao M, Wang Y, Chu J, Zhuang Y. Evaluation of mixing effect and shear stress of different impeller combinations on nemadectin fermentation. Process Biochem 2020. [DOI: 10.1016/j.procbio.2020.02.018] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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25
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Esperança MN, Mendes CE, Rodriguez GY, Cerri MO, Béttega R, Badino AC. Sparger design as key parameter to define shear conditions in pneumatic bioreactors. Biochem Eng J 2020. [DOI: 10.1016/j.bej.2020.107529] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
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26
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Li C, Teng X, Peng H, Yi X, Zhuang Y, Zhang S, Xia J. Novel scale-up strategy based on three-dimensional shear space for animal cell culture. Chem Eng Sci 2020. [DOI: 10.1016/j.ces.2019.115329] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/17/2022]
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27
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Wang G, Haringa C, Tang W, Noorman H, Chu J, Zhuang Y, Zhang S. Coupled metabolic-hydrodynamic modeling enabling rational scale-up of industrial bioprocesses. Biotechnol Bioeng 2019; 117:844-867. [PMID: 31814101 DOI: 10.1002/bit.27243] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/11/2019] [Revised: 11/28/2019] [Accepted: 11/30/2019] [Indexed: 12/13/2022]
Abstract
Metabolomics aims to address what and how regulatory mechanisms are coordinated to achieve flux optimality, different metabolic objectives as well as appropriate adaptations to dynamic nutrient availability. Recent decades have witnessed that the integration of metabolomics and fluxomics within the goal of synthetic biology has arrived at generating the desired bioproducts with improved bioconversion efficiency. Absolute metabolite quantification by isotope dilution mass spectrometry represents a functional readout of cellular biochemistry and contributes to the establishment of metabolic (structured) models required in systems metabolic engineering. In industrial practices, population heterogeneity arising from fluctuating nutrient availability frequently leads to performance losses, that is reduced commercial metrics (titer, rate, and yield). Hence, the development of more stable producers and more predictable bioprocesses can benefit from a quantitative understanding of spatial and temporal cell-to-cell heterogeneity within industrial bioprocesses. Quantitative metabolomics analysis and metabolic modeling applied in computational fluid dynamics (CFD)-assisted scale-down simulators that mimic industrial heterogeneity such as fluctuations in nutrients, dissolved gases, and other stresses can procure informative clues for coping with issues during bioprocessing scale-up. In previous studies, only limited insights into the hydrodynamic conditions inside the industrial-scale bioreactor have been obtained, which makes case-by-case scale-up far from straightforward. Tracking the flow paths of cells circulating in large-scale bioreactors is a highly valuable tool for evaluating cellular performance in production tanks. The "lifelines" or "trajectories" of cells in industrial-scale bioreactors can be captured using Euler-Lagrange CFD simulation. This novel methodology can be further coupled with metabolic (structured) models to provide not only a statistical analysis of cell lifelines triggered by the environmental fluctuations but also a global assessment of the metabolic response to heterogeneity inside an industrial bioreactor. For the future, the industrial design should be dependent on the computational framework, and this integration work will allow bioprocess scale-up to the industrial scale with an end in mind.
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Affiliation(s)
- Guan Wang
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology, Shanghai, People's Republic of China
| | - Cees Haringa
- Transport Phenomena, Chemical Engineering Department, Delft University of Technology, Delft, The Netherlands.,DSM Biotechnology Center, Delft, The Netherlands
| | - Wenjun Tang
- DSM Biotechnology Center, Delft, The Netherlands
| | - Henk Noorman
- DSM Biotechnology Center, Delft, The Netherlands.,Bioprocess Engineering, Department of Biotechnology, Delft University of Technology, Delft, The Netherlands
| | - Ju Chu
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology, Shanghai, People's Republic of China
| | - Yingping Zhuang
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology, Shanghai, People's Republic of China
| | - Siliang Zhang
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology, Shanghai, People's Republic of China
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Böhm L, Hohl L, Bliatsiou C, Kraume M. Multiphase Stirred Tank Bioreactors – New Geometrical Concepts and Scale‐up Approaches. CHEM-ING-TECH 2019. [DOI: 10.1002/cite.201900165] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Lutz Böhm
- Technische Universität BerlinChair of Chemical and Process Engineering, FH6-1 Straße des 17. Juni 135 10623 Berlin Germany
| | - Lena Hohl
- Technische Universität BerlinChair of Chemical and Process Engineering, FH6-1 Straße des 17. Juni 135 10623 Berlin Germany
| | - Chrysoula Bliatsiou
- Technische Universität BerlinChair of Chemical and Process Engineering, FH6-1 Straße des 17. Juni 135 10623 Berlin Germany
| | - Matthias Kraume
- Technische Universität BerlinChair of Chemical and Process Engineering, FH6-1 Straße des 17. Juni 135 10623 Berlin Germany
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29
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Naoum JN, Alshanski I, Gitlin-Domagalska A, Bentolila M, Gilon C, Hurevich M. Diffusion-Enhanced Amide Bond Formation on a Solid Support. Org Process Res Dev 2019. [DOI: 10.1021/acs.oprd.9b00398] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
| | | | - Agata Gitlin-Domagalska
- Department of Molecular Biochemistry, Faculty of Chemistry, University of Gdansk, Wita Stwosza 63, 80-308 Gdansk, Poland
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30
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Application of CFD to Analyze the Hydrodynamic Behaviour of a Bioreactor with a Double Impeller. Processes (Basel) 2019. [DOI: 10.3390/pr7100694] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/14/2023] Open
Abstract
Stirred bioreactors are commonly used unit operations in the pharmaceutical industry. In this study, computational fluid dynamics (CFD) was used in order to analyze the influence of the impeller configuration (Segment–Segment and Segment–Rushton impeller configurations) and the impeller rotational speed (an operational parameter) on the hydrodynamic behaviour and mixing performance of a bioreactor equipped with a double impeller. A relatively close agreement between the power values obtained from the CFD model and those measured experimentally was observed. Various parameters such as velocity profiles, stress generated by impellers due to the turbulence and velocity gradient, flow number, and mixing time were used to compare the CFD simulations. It was observed that the impeller’s RPM could change the intensity of the interaction between the impellers when a Segment–Rushton impeller was used. In general, increasing the RPM led to an increase in total power and the stress acting on the cells and to a shorter mixing time. At a constant RPM, the Segment–Rushton impeller configuration had higher total power and stress acting on cells compared to the Segment–Segment impeller configuration. At lower RPM values (i.e., 50 and 100), the Segment–Segment impeller provided a shorter mixing time. Conversely, at the highest RPM (i.e., 150) the Segment–Rushton impeller had a shorter mixing time compared to the Segment–Segment impeller; this was attributed to the high level of turbulence generated with the former impeller configuration at high RPM.
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31
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Haringa C, Mudde RF, Noorman HJ. From industrial fermentor to CFD-guided downscaling: what have we learned? Biochem Eng J 2018. [DOI: 10.1016/j.bej.2018.09.001] [Citation(s) in RCA: 27] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/27/2022]
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32
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Salierno G, Maestri M, Piovano S, Cassanello M, Cardona MA, Hojman D, Somacal H. Features of the motion of gel particles in a three-phase bubble column under foaming and non-foaming conditions. Chin J Chem Eng 2018. [DOI: 10.1016/j.cjche.2018.03.026] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/10/2023]
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33
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González-Cabaleiro R, Mitchell AM, Smith W, Wipat A, Ofiţeru ID. Heterogeneity in Pure Microbial Systems: Experimental Measurements and Modeling. Front Microbiol 2017; 8:1813. [PMID: 28970826 PMCID: PMC5609101 DOI: 10.3389/fmicb.2017.01813] [Citation(s) in RCA: 35] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/29/2017] [Accepted: 09/05/2017] [Indexed: 01/02/2023] Open
Abstract
Cellular heterogeneity influences bioprocess performance in ways that until date are not completely elucidated. In order to account for this phenomenon in the design and operation of bioprocesses, reliable analytical and mathematical descriptions are required. We present an overview of the single cell analysis, and the mathematical modeling frameworks that have potential to be used in bioprocess control and optimization, in particular for microbial processes. In order to be suitable for bioprocess monitoring, experimental methods need to be high throughput and to require relatively short processing time. One such method used successfully under dynamic conditions is flow cytometry. Population balance and individual based models are suitable modeling options, the latter one having in particular a good potential to integrate the various data collected through experimentation. This will be highly beneficial for appropriate process design and scale up as a more rigorous approach may prevent a priori unwanted performance losses. It will also help progressing synthetic biology applications to industrial scale.
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Affiliation(s)
- Rebeca González-Cabaleiro
- School of Engineering, Chemical Engineering, Newcastle UniversityNewcastle upon Tyne, United Kingdom
| | - Anca M Mitchell
- School of Engineering, Chemical Engineering, Newcastle UniversityNewcastle upon Tyne, United Kingdom
| | - Wendy Smith
- Interdisciplinary Computing and Complex BioSystems (ICOS), School of ComputingNewcastle University, Newcastle upon Tyne, United Kingdom
| | - Anil Wipat
- Interdisciplinary Computing and Complex BioSystems (ICOS), School of ComputingNewcastle University, Newcastle upon Tyne, United Kingdom
| | - Irina D Ofiţeru
- School of Engineering, Chemical Engineering, Newcastle UniversityNewcastle upon Tyne, United Kingdom
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Amani A, Jalilnejad E. CFD modeling of formaldehyde biodegradation in an immobilized cell bioreactor with disc-shaped Kissiris support. Biochem Eng J 2017. [DOI: 10.1016/j.bej.2017.02.014] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
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