Investigation and Modeling of Gas-Liquid Mass Transfer in a Sparged and Non-Sparged Continuous Stirred Tank Reactor with Potential Application in Syngas Fermentation

Stirring-Controlled Synthesis of Ultrastable, Fluorescent Silver Nanoclusters

This paper describes how macroscopic stirring of a reaction mixture can be used to produce nanostructures exhibiting properties not readily achievable via other protocols. In particular, it is shown that by simply adjusting the stirring rate, a standard glutathione-based method-to date, used to produce only marginally stable fluorescent silver nanoclusters, Ag NCs-can be boosted to yield nanoclusters retaining fluorescence for unprecedented periods of over 2 years. This enhancement derives not simply from increased homogenization of the reaction mixture but mainly from an appropriately timed delivery of oxygen from above the reaction mixture. In effect, oxygen serves as a reagent that dictates size, structure, stability, and functional properties of the growing nanoobjects.

Development of Lab-Scale Continuous Stirred-Tank Reactor as Flow Process Tool for Oxidation Reactions Using Molecular Oxygen

The use of sustainable oxidants is of great interest to the chemical industry, considering the importance of oxidation reactions for the manufacturing of chemicals and society's growing awareness of its environmental impact. Molecular oxygen (O2), with an almost optimal atom efficiency in oxidation reactions, presents one of the most attractive alternatives to common reagents that are not only toxic in most cases but produce stoichiometric amounts of waste that must be treated. However, fire and explosion safety concerns, especially when used in combination with organic solvents, restrict its easy use. Here, we use state-of-the-art 3D printing and experimental feedback to develop a miniature continuous stirred-tank reactor (mini-CSTR) that enables efficient use of O2 as an oxidant in organic chemistry. Outstanding heat dissipation properties, achieved through integrated jacket cooling and a high surface-to-volume ratio, allow for a safe operation of the exothermic oxidation of 2-ethylhexanal, surpassing previously reported product selectivity. Moving well beyond the proof-of-concept stage, we characterize and illustrate the reactor's potential in the gas-liquid-solid triphasic synthesis of an endoperoxide precursor of antileishmanial agents. The custom-designed magnetic overhead stirring unit provides improved stirring efficiency, facilitating the handling of suspensions and, in combination with the borosilicate gas dispersion plate, leading to an optimized gas-liquid interface. These results underscore the immense potential that lies within the use of mini-CSTR in sustainable chemistry.

Multiphasic Continuous-Flow Reactors for Handling Gaseous Reagents in Organic Synthesis: Enhancing Efficiency and Safety in Chemical Processes

The use of reactive gaseous reagents for the production of active pharmaceutical ingredients (APIs) remains a scientific challenge due to safety and efficiency limitations. The implementation of continuous-flow reactors has resulted in rapid development of gas-handling technology because of several advantages such as increased interfacial area, improved mass- and heat transfer, and seamless scale-up. This technology enables shorter and more atom-economic synthesis routes for the production of pharmaceutical compounds. Herein, we provide an overview of literature from 2016 onwards in the development of gas-handling continuous-flow technology as well as the use of gases in functionalization of APIs.

Probing efficient microbial CO2 utilisation through metabolic and process modelling

Acetogenic gas fermentation is increasingly studied as a promising technology to upcycle carbon-rich waste gasses. Currently the product range is limited, and production yields, rates and titres for a number of interesting products do not allow for economically viable processes. By pairing process modelling and host-agnostic metabolic modelling, we compare fermentation conditions and various products to optimise the processes. The models were then used in a simulation of an industrial-scale bubble column reactor. We find that increased temperatures favour gas transfer rates, particularly for the valuable and limiting H2 , while furthermore predicting an optimal feed composition of 9:1 mol H2 to mol CO2 . Metabolically, the increased non-growth associated maintenance requirements of thermophiles favours the formation of catabolic products. To assess the expansion of the product portfolio beyond acetate, both a product volatility analysis and a metabolic pathway model were implemented. In-situ recovery of volatile products is shown to be within range for acetone but challenging due to the extensive evaporation of water, while the direct production of more valuable compounds by acetogens is metabolically unfavourable compared to acetate and ethanol. We discuss alternative approaches to overcome these challenges to utilise acetogenic CO2 fixation to produce a wider range of carbon negative chemicals.

Hydrogenase-based oxidative biocatalysis without oxygen

Biocatalysis-based synthesis can provide a sustainable and clean platform for producing chemicals. Many oxidative biocatalytic routes require the cofactor NAD⁺ as an electron acceptor. To date, NADH oxidase (NOX) remains the most widely applied system for NAD⁺ regeneration. However, its dependence on O₂ implies various technical challenges in terms of O₂ supply, solubility, and mass transfer. Here, we present the suitability of a NAD⁺ regeneration system in vitro based on H₂ evolution. The efficiency of the hydrogenase-based system is demonstrated by integrating it into a multi-enzymatic cascade to produce ketoacids from sugars. The total NAD⁺ recycled using the hydrogenase system outperforms NOX in all different setups reaching up to 44,000 mol per mol enzyme. This system proves to be scalable and superior to NOX in terms of technical simplicity, flexibility, and total output. Furthermore, the system produces only green H₂ as a by-product even in the presence of O₂.

Reactor Designs and Configurations for Biological and Bioelectrochemical C1 Gas Conversion: A Review

Microbial C1 gas conversion technologies have developed into a potentially promising technology for converting waste gases (CO₂, CO) into chemicals, fuels, and other materials. However, the mass transfer constraint of these poorly soluble substrates to microorganisms is an important challenge to maximize the efficiencies of the processes. These technologies have attracted significant scientific interest in recent years, and many reactor designs have been explored. Syngas fermentation and hydrogenotrophic methanation use molecular hydrogen as an electron donor. Furthermore, the sequestration of CO₂ and the generation of valuable chemicals through the application of a biocathode in bioelectrochemical cells have been evaluated for their great potential to contribute to sustainability. Through a process termed microbial chain elongation, the product portfolio from C1 gas conversion may be expanded further by carefully driving microorganisms to perform acetogenesis, solventogenesis, and reverse β-oxidation. The purpose of this review is to provide an overview of the various kinds of bioreactors that are employed in these microbial C1 conversion processes.

Towards enhancement of gas-liquid mass transfer in bioelectrochemical systems: Validation of a robust CFD model

Mass transfer has been identified as a major bottleneck in gas fermentation and microbial conversion of carbon dioxide to chemicals. We present a pragmatic and validated Computational Fluid Dynamics (CFD) model for mass transfer in bioelectrochemical systems. Experiments were conducted to measure mixing times and mass transfer in a Duran bottle and an H-cell. An Eulerian-Eulerian framework with a simplified model for the bubble size distribution (BSD) was developed that utilized only one additional equation for the bubble number density while including the breakup and coalescence. Validations of the CFD model for mixing times showed that the predictions were within the confidence intervals of the measurements, verifying the model's capability in simulating the hydrodynamics. Further validations were performed using constant and varying bubble diameters for the mass transfer. The results showed the benefits of a simplified BSD model, as it yielded improvements of seven and four times in accuracy when assessed against the experimental data for the Duran bottle and H-cell, respectively. Modeling of the H-cell predicted that a lower stirring rate improves mass transfer compared with higher stirring rates, which is of great importance when designing microbial cultivation processes. The model offers a feasible framework for advanced modeling of gas fermentation and microbial electrosynthesis.

Anoxic biogas biodesulfurization promoting elemental sulfur production in a Continuous Stirred Tank Bioreactor

Biological desulfurization of biogas has been extensively studied using biotrickling filters (BTFs). However, the accumulation of elemental sulfur (S°) on the packing material limits the use of this technology. To overcome this issue, the use of a continuous stirred tank bioreactor (CSTBR) under anoxic conditions for biogas desulfurization and S° production is proposed in the present study. The effect of the main parameters (stirring speed, N/S molar ratio, hydraulic residence time (HRT) and gas residence time (GRT)) on the bioreactor performance was studied. Under an inlet load (IL) of 100 g S-H₂S m^-3 h^-1 and a GRT of 119 s, the CSTBR optimal operating conditions were 60 rpm, N/S molar ratio of 1.1 and a HRT of 42 h, in which a removal efficiency (RE) and S° production of 98.6 ± 0.4 % and 88 % were obtained, respectively. Under a GRT of 41 s and an IL of 232 g S-H₂S m^-3 h^-1 the maximum elimination capacity (EC) of 166.0 ± 7.2 g S-H₂S m^-3 h^-1 (RE = 71.7 ± 3.1 %) was obtained. A proportional-integral feedback control strategy was successfully applied to the bioreactor operated under a stepped variable IL.

Biocatalysis and biomass conversion: enabling a circular economy

This paper is based on a lecture presented to the Royal Society in London on 24 June 2019. Two of the grand societal and technological challenges of the twenty-first century are the 'greening' of chemicals manufacture and the ongoing transition to a sustainable, carbon neutral economy based on renewable biomass as the raw material, a so-called bio-based economy. These challenges are motivated by the need to eliminate environmental degradation and mitigate climate change. In a bio-based economy, ideally waste biomass, particularly agricultural and forestry residues and food supply chain waste, are converted to liquid fuels, commodity chemicals and biopolymers using clean, catalytic processes. Biocatalysis has the right credentials to achieve this goal. Enzymes are biocompatible, biodegradable and essentially non-hazardous. Additionally, they are derived from inexpensive renewable resources which are readily available and not subject to the large price fluctuations which undermine the long-term commercial viability of scarce precious metal catalysts. Thanks to spectacular advances in molecular biology the landscape of biocatalysis has dramatically changed in the last two decades. Developments in (meta)genomics in combination with 'big data' analysis have revolutionized new enzyme discovery and developments in protein engineering by directed evolution have enabled dramatic improvements in their performance. These developments have their confluence in the bio-based circular economy. This article is part of a discussion meeting issue 'Science to enable the circular economy'.