Development of a hybrid bio-purification process of lactic acid solutions employing an engineered E. coli strain in a membrane bioreactor

BACKGROUND

A potential alternative to lactic acid production through sugar fermentation is its recovery from grass silage leachate. The separation and purification of lactic acid from fermentation broths remain a key issue, as it amounts to up to 80% of its industrial production cost. In this study, a genetically engineered E. coli strain (A1:ldhA), that cannot catabolize lactic acid, has been used to selectively remove impurities from a synthetic medium comprising typical components (i.e., glucose and acetic acid) of green grass silage leachate. A systematic approach has been followed to provide a proof-of-concept for a bio-purification process of lactic acid solutions in a membrane bioreactor operating in semi-continuous mode.

RESULTS

The synthetic medium composition was initially optimized in shake-flasks experiments, followed by scale-up in bench-scale bioreactor. Complete (i.e., 100%) and 60.4% removal for glucose and acetic acid, respectively, has been achieved in batch bioreactor experiments with a synthetic medium comprising 0.5 g/L glucose and 0.5 g/L acetic acid as carbon sources, and 10 g/L lactic acid; no lactic acid catabolism was observed in all batch fermentation tests. Afterwards, a hybrid biotechnological process combining semi-continuous bioreactor fermentation and ultrafiltration membrane separation (membrane bioreactor) was applied to in-situ separate purified medium from the active cells. The process was assessed under different semi-continuous operating conditions, resulting in a bacteria-free effluent and 100% glucose and acetic acid depletion, with no lactic acid catabolism, thus increasing the purity of the synthetic lactic acid solution.

CONCLUSIONS

The study clearly demonstrated that a bio-purification process for lactic acid employing the engineered E. coli strain cultivated in a membrane bioreactor is a technically feasible concept, paving the way for further technological advancement.

Design of a Gas Permeation and Pervaporation Membrane Model for an Open Source Process Simulation Tool

Gas permeation and pervaporation are technologies that emerged several decades ago. Even though they have discovered increasing popularity for industrial separation processes, they are not represented equally within process simulation tools except for commercial systems. The availability of such a numerical solution shall be extended due to the design of a membrane model with Visual Basic based on the solution-diffusion model. Although this works approach is presented for a specific process simulator application, the algorithm can generally be transferred to any other programming language and process simulation solver, which allows custom implementations or modeling. Furthermore, the modular design of the model enables its further development by operators through the integration of physical effects. A comparison with experimental data of gas permeation and pervaporation applications as well as other published simulation data delivers either good accordance with the results or negligible deviations of less than 1% from other data.

Titanium-Pillared Clay: Preparation Optimization, Characterization, and Artificial Neural Network Modeling

Titanium-pillared clay (Ti-PILC), as one of the most suitable types of porous adsorbents/(photo)catalysts, was prepared from a local type of Iranian clay and titanium isopropoxide. The production process was optimized by changing three operating parameters, including the clay suspension concentration (in the range of 0.5–10% w/v), the H⁺/Ti ratio (2–8 mol/mol), and the calcination temperature (300–700 °C). The largest specific surface area for the Ti-PILC was about 164 m²/g under the clay suspension of 0.5% w/v, H⁺/Ti = 6, with a surface area 273% larger than that of the raw clay. The surface areas obtained from more concentrated clay suspensions were, however, comparable (159 m²/g for 3% w/v clay and H⁺/Ti = 4). An increase in the calcination temperature has a negative effect on the porous texture of Ti-PILC, but based on modeling with artificial neural networks, its contribution was only 7%. Clay suspension and H⁺/Ti ratio play a role of 56 and 37% of the specific surface area. The presence of rutile phase, and in some cases anatase phase of TiO₂ crystals was detected. FTIR and SEM investigations of Ti-PILCs produced under different operating parameters were analyzed.

Dataset for the simulated biomass pyrolysis in rotary kilns with varying particle residence time distributions

Slow pyrolysis of biomass is commonly performed in rotary kilns. The effect of the particle residence time distribution on biomass conversion is often neglected when numerically modeling such systems. But this effect might be significant under certain conditions. The data presented here are results of numerical simulation of the biomass pyrolysis in rotary kilns under numerous operating conditions and levels of axial dispersion of biomass particles. The varied operating conditions are the kiln diameter ( D = 0.1 -1 m), the ratio of particle to kiln diameter ( d / D = 5 × 10 - 3 - 40 × 10 - 3 ), the ratio of kiln length to kiln diameter ( L / D = 1 -10), the kiln's inclination angle ( β = 0.1 -8∘ ), the Froude number ( Fr = 10 - 3 - 10 - 2 ), the rotational Reynolds number ( Re = 10 2 - 16 × 10 3 ), and the Péclet number ( Pe = 5 -100). Data of 13,851 single case simulations are provided with this article. This includes the mean particle residence time, gas, bed and kiln wall temperatures, solid and gaseous species mass flows, heat fluxes, and the solid bed height over the kiln length. These comprehensive data have the potential to help in modeling, design, analysis, and optimization of rotary kilns used for the pyrolysis of biomass. The main characterization and interpretation is presented in the related main research paper by Pichler et al. (2021)[1].

Ethyl lactate production by reactive distillation - optimization of reaction kinetics and energy efficiency

Background: Ethyl lactate is an environmentally benign solvent, which could substitute petrol-based volatile organic compounds (VOCs) in many applications if production costs are reduced. It is usually produced by the esterification of lactic acid with ethanol - two important chemical building blocks of biorefineries that are available at industrial scale. Reactive distillation is a promising alternative production process, which utilises process intensification to increase energy efficiency and space-time yield by enhancing the reaction kinetics. Methods: In this work, process intensification of ethyl lactate production by means of distillation was analysed with special focus on the efficient separation of water. Different setups were evaluated. The feedstock requirements were studied and the process was optimized regarding reaction kinetics in experiments on laboratory level. The preparation of anhydrous starting mixtures for ethyl lactate formation was tested in batch experiments and applied to reactive distillation. The simultaneous distillation was optimized and assessed for its energy efficiency. For this purpose, integrated reactive distillation was compared to a simple setup for distillation enhanced esterification. Results: It was found that an optimized serial setup of reactors and distillation steps can offer similar process intensification at a lower distillate rate compared to simultaneous reactive distillation and is therefore more energy efficient. Moreover, the serial setup is more flexible and straight-forward to regulate and scale-up. Conclusions: Based on the experimental results, the optimal setup and parameters of a continuous process for ethyl lactate production by distillation enhanced esterification was presented.

Considerations on Temperature Dependent Effective Diffusion and Permeability of Natural Clays

A series of porous clay samples prepared at different pretreatment temperatures have been tested in a diffusion chamber. Diffusivity and permeability were examined in a temperature range from ambient to 900 °C. Gaseous mixtures of O₂, CO₂, and N₂ have been applied, as these species are the relevant gases in the context of clay brick firing and similar thermochemical processes. Diffusive transport characteristics have been determined by means of the mean transport-pore model, and permeability has been evaluated by Darcy’s law. CO₂ diffusivity increased strongly with temperature, whereas O₂ diffusion was limited to a certain level. It is proposed that one should consider CO₂ surface diffusion in order to explain this phenomenon. The diffusion model was expanded and surface diffusion was included in the model equation. The results of the model fit reflected the important role of incorporated carbonates of the clay foundation in gas-phase (molecular or Knudsen) diffusivity. CO₂ surface diffusion was observed to exhibit similar coefficients for two different investigated clays, and is therefore indicated as a property of natural clays. Permeability showed a progressive rise with temperature, in line with related literature.

Non-parametric dynamical estimation of blood flow rate, pressure difference and viscosity for a miniaturized blood pump

Blood pumps are becoming increasingly important for medical devices. They are used to assist and control the blood flow and blood pressure in the patient's body. To accurately control blood pumps, information about important hydrodynamic parameters such as blood flow rate, pressure difference and viscosity is needed. These parameters are difficult to measure online. Therefore, an accurate estimation of these parameters is crucial for the effective operation of implantable blood pumps. In this study, in vitro tests with bovine blood were conducted to collect data about the non-linear dependency of blood flow rate, flow resistance (pressure difference) and whole blood viscosity on motor current and rotation speed of a prototype blood pump. Gaussian process regression models are then used to model the non-linear mappings from motor current and rotation speed to the hydrodynamic variables of interest. The performance of the estimation is evaluated for all three variables and shows very high accuracy. For blood flow rate - correlation coefficient (r2) = 1, root mean squared error (RMSE) = 0.31 ml min^-1, maximal error (ERRmax) = 9.31 ml min^-1; for pressure r2 = 1, RMSE = 0.09 mmHg, ERRmax = 8.34 mmHg; and for viscosity r2 = 1,RMSE = 0.09 mPa.s, ERRmax = 0.31 mPa⋅s. The current findings suggest that this method can be employed for highly accurate online estimation of essential hydrodynamic parameters for implantable blood pumps.

A Microfluidic Multisize Spheroid Array for Multiparametric Screening of Anticancer Drugs and Blood-Brain Barrier Transport Properties

Physiological-relevant in vitro tissue models with their promise of better predictability have the potential to improve drug screening outcomes in preclinical studies. Despite the advances of spheroid models in pharmaceutical screening applications, variations in spheroid size and consequential altered cell responses often lead to nonreproducible and unpredictable results. Here, a microfluidic multisize spheroid array is established and characterized using liver, lung, colon, and skin cells as well as a triple-culture model of the blood-brain barrier (BBB) to assess the effects of spheroid size on (a) anticancer drug toxicity and (b) compound penetration across an advanced BBB model. The reproducible on-chip generation of 360 spheroids of five dimensions on a well-plate format using an integrated microlens technology is demonstrated. While spheroid size-related IC50 values vary up to 160% using the anticancer drugs cisplatin (CIS) or doxorubicin (DOX), reduced CIS:DOX drug dose combinations eliminate all lung microtumors independent of their sizes. A further application includes optimizing cell seeding ratios and size-dependent compound uptake studies in a perfused BBB model. Generally, smaller BBB-spheroids reveal an 80% higher compound penetration than larger spheroids while verifying the BBB opening effect of mannitol and a spheroid size-related modulation on paracellular transport properties.

Water as a Blood Model for Determination of CO2 Removal Performance of Membrane Oxygenators

CO₂ removal via membrane oxygenators has become an important and reliable clinical technique. Nevertheless, oxygenators must be further optimized to increase CO₂ removal performance and to reduce severe side effects. Here, in vitro tests with water can significantly reduce costs and effort during development. However, they must be able to reasonably represent the CO₂ removal performance observed with blood. In this study, the deviation between the CO₂ removal rate determined in vivo with porcine blood from that determined in vitro with water is quantified. The magnitude of this deviation (approx. 10%) is consistent with results reported in the literature. To better understand the remaining difference in CO₂ removal rate and in order to assess the application limits of in vitro water tests, CFD simulations were conducted. They allow to quantify and investigate the influences of the differing fluid properties of blood and water on the CO₂ removal rate. The CFD results indicate that the main CO₂ transport resistance, the diffusional boundary layer, behaves generally differently in blood and water. Hence, studies of the CO₂ boundary layer should be preferably conducted with blood. In contrast, water tests can be considered suitable for reliable determination of the total CO₂ removal performance of oxygenators.

Animal blood in translational research: How to adjust animal blood viscosity to the human standard

Animal blood is used in mock circulations or in forensic bloodstain pattern analysis. Blood viscosity is important in these settings as it determines the driving pressure through biomedical devices and the shape of the bloodstain. However, animal blood can never exactly mimic human blood due to erythrocyte properties differing among species. This results in the species-specific shear thinning behavior of blood suspensions, and it is therefore not enough to adjust the hematocrit of an animal blood sample to mimic the behavior of human blood over the entire range of shear rates that are present in the body. In order to optimize experiments that require animal blood, we need models to adapt the blood samples. We here offer mathematical models derived for each species using a multi linear regression approach to describe the influence of shear rate, hematocrit, and temperature on blood viscosity. Results show that pig blood cannot be recommended for experiments at low flow conditions (<200 s-1 ) even though erythrocyte properties are similar in pigs and humans. However, pig blood mimics human blood excellently at high flow condition. Horse blood is unsuitable as experimental model in this regard. For several studied conditions, sheep blood was the closest match to human blood viscosity among the tested species.

Suitable CO2 Solubility Models for Determination of the CO2 Removal Performance of Oxygenators

CO₂ removal via membrane oxygenators during lung protective ventilation has become a reliable clinical technique. For further optimization of oxygenators, accurate prediction of the CO₂ removal rate is necessary. It can either be determined by measuring the CO₂ content in the exhaust gas of the oxygenator (sweep flow-based) or using blood gas analyzer data and a CO₂ solubility model (blood-based). In this study, we determined the CO₂ removal rate of a prototype oxygenator utilizing both methods in in vitro trials with bovine and in vivo trials with porcine blood. While the sweep flow-based method is reliably accurate, the blood-based method depends on the accuracy of the solubility model. In this work, we quantified performances of four different solubility models by calculating the deviation of the CO₂ removal rates determined by both methods. Obtained data suggest that the simplest model (Loeppky) performs better than the more complex ones (May, Siggaard-Anderson, and Zierenberg). The models of May, Siggaard-Anderson, and Zierenberg show a significantly better performance for in vitro bovine blood data than for in vivo porcine blood data. Furthermore, the suitability of the Loeppky model parameters for bovine blood (in vitro) and porcine blood (in vivo) is evaluated.

CuSO4/[Cu(NH3)4]SO4-Composite Thermochemical Energy Storage Materials

The thermochemical energy-storage material couple CuSO₄/[Cu(NH₃)₄]SO₄ combines full reversibility, application in a medium temperature interval (<350 °C), and fast liberation of stored heat. During reaction with ammonia, a large change in the sulfate solid-state structure occurs, resulting in a 2.6-fold expansion of the bulk material due to NH₃ uptake. In order to limit this volume work, as well as enhance the thermal conductivity of the solid material, several composites of anhydrous CuSO₄ with inorganic inert support materials were prepared and characterized with regard to their energy storage density, reversibility of the storage reaction, thermal conductivity, and particle morphology. The best thermochemical energy storage properties were obtained for a 10:1 CuSO₄-sepiolite composite, combining an attractive energy storage density with slightly improved thermal conductivity and decreased bulk volume work compared to the pure salt.

Computational fluid dynamics analysis of char conversion in Sandia's pressurized entrained flow reactor

Design and analysis of practical reactors utilizing solid feedstocks rely on reaction rate parameters that are typically generated in lab-scale reactors. Evaluation of the reaction rate information often relies on assumptions of uniform temperature, velocity, and species distributions in the reactor, in lieu of detailed measurements that provide local information. This assumption might be a source of substantial error, since reactor designs can impose significant inhomogeneities, leading to data misinterpretation. Spatially resolved reactor simulations help understand the key processes within the reactor and support the identification of severe variations of temperature, velocity, and species distributions. In this work, Sandia's pressurized entrained flow reactor is modeled to identify inhomogeneities in the reaction zone. Tracer particles are tracked through the reactor to estimate the residence times and burnout ratio of introduced coal char particles in gasifying environments. The results reveal a complex mixing environment for the cool gas and particles entering the reactor along the centerline and the main high-speed hot gas reactor flow. Furthermore, the computational fluid dynamics (CFD) results show that flow asymmetries are introduced through the use of a horizontal gas pre-heating section that connects to the vertical reactor tube. Computed particle temperatures and residence times in the reactor differ substantially from the idealized plug flow conditions typically evoked in interpreting experimental measurements. Furthermore, experimental measurements and CFD analysis of heat flow through porous refractory insulation suggest that for the investigated conditions (1350 °C, <20 atm), the thermal conductivity of the insulation does not increase substantially with increasing pressure.

Estimation Methods for Viscosity, Flow Rate and Pressure from Pump-Motor Assembly Parameters

Blood pumps have found applications in heart support devices, oxygenators, and dialysis systems, among others. Often, there is no room for sensors, or the sensors are simply unreliable when long-term operation is required. However, control systems rely on those hard-to-measure parameters, such as blood flow rate and pressure difference, thus their estimation takes a central role in the development process of such medical devices. The viscosity of the blood not only influences the estimation of those parameters but is often a parameter that is of great interest to both doctors and engineers. In this work, estimation methods for blood flow rate, pressure difference, and viscosity are presented using Gaussian process regression models. Different water–glycerol mixtures were used to model blood. Data was collected from a custom-built blood pump, designed for intracorporeal oxygenators in an in vitro test circuit. The estimation was performed from motor current and motor speed measurements and its accuracy was measured for: blood flow rate r² = 0.98, root mean squared error (RMSE) = 46 mL^.min⁻¹; pressure difference r² = 0.98, RMSE = 8.7 mmHg; and viscosity r² = 0.98, RMSE = 0.049 mPa^.s. The results suggest that the presented methods can be used to accurately predict blood flow rate, pressure, and viscosity online.

Microfluidic nutrient gradient-based three-dimensional chondrocyte culture-on-a-chip as an in vitro equine arthritis model

In this work, we describe a microfluidic three-dimensional (3D) chondrocyte culture mimicking in vivo articular chondrocyte morphology, cell distribution, metabolism, and gene expression. This has been accomplished by establishing a physiologic nutrient diffusion gradient across the simulated matrix, while geometric design constraints of the microchambers drive native-like cellular behavior. Primary equine chondrocytes remained viable for the extended culture time of 3 weeks and maintained the low metabolic activity and high Sox9, aggrecan, and Col2 expression typical of articular chondrocytes. Our microfluidic 3D chondrocyte microtissues were further exposed to inflammatory cytokines to establish an animal-free, in vitro osteoarthritis model. Results of our study indicate that our microtissue model emulates the basic characteristics of native cartilage and responds to biochemical injury, thus providing a new foundation for exploration of osteoarthritis pathophysiology in both human and veterinary patients.

Basic Performance Tests of the MILL Intravascular CO2 Removal Catheter

Currently available treatment methods for acute lung failure show high rates of complications. There is an urgent need for alternative treatment methods. A catheter device which can be minimal invasively inserted into the vena cava for intracorporeal gas exchange was developed. Main components of the device are a drive unit and a membrane module. In this study, the flow behavior in a vena cava model with inserted catheter prototype was investigated in experiments and basic computational fluid dynamic (CFD) simulations. Main findings are that the miniature blood pump has suitable characteristics and generates sufficient power to overcome the pressure drop induced in the membrane module, and that the design of the membrane outlet might be critical to avoid additional pressure losses. Parts manufactured with a high resolution 3D printer have proven to be suitable for the prototyping process.

Cycle Stability and Hydration Behavior of Magnesium Oxide and Its Dependence on the Precursor-Related Particle Morphology

Thermochemical energy storage is considered as an auspicious method for the recycling of medium-temperature waste heat. The reaction couple Mg(OH)₂⁻MgO is intensely investigated for this purpose, suffering so far from limited cycle stability. To overcome this issue, Mg(OH)₂, MgCO₃, and MgC₂O₄·2H₂O were compared as precursor materials for MgO production. Depending on the precursor, the particle morphology of the resulting MgO changes, resulting in different hydration behavior and cycle stability. Agglomeration of the material during cyclization was identified as main reason for the decreased reactivity. Immersion of the spent material in liquid H₂O decomposes the agglomerates restoring the initial reactivity of the material, thus serving as a regeneration step.

Every Breath You Take: Non-invasive Real-Time Oxygen Biosensing in Two- and Three-Dimensional Microfluidic Cell Models

Knowledge on the availability of dissolved oxygen inside microfluidic cell culture systems is vital for recreating physiological-relevant microenvironments and for providing reliable and reproducible measurement conditions. It is important to highlight that in vivo cells experience a diverse range of oxygen tensions depending on the resident tissue type, which can also be recreated in vitro using specialized cell culture instruments that regulate external oxygen concentrations. While cell-culture conditions can be readily adjusted using state-of-the-art incubators, the control of physiological-relevant microenvironments within the microfluidic chip, however, requires the integration of oxygen sensors. Although several sensing approaches have been reported to monitor oxygen levels in the presence of cell monolayers, oxygen demands of microfluidic three-dimensional (3D)-cell cultures and spatio-temporal variations of oxygen concentrations inside two-dimensional (2D) and 3D cell culture systems are still largely unknown. To gain a better understanding on available oxygen levels inside organ-on-a-chip systems, we have therefore developed two different microfluidic devices containing embedded sensor arrays to monitor local oxygen levels to investigate (i) oxygen consumption rates of 2D and 3D hydrogel-based cell cultures, (ii) the establishment of oxygen gradients within cell culture chambers, and (iii) influence of microfluidic material (e.g., gas tight vs. gas permeable), surface coatings, cell densities, and medium flow rate on the respiratory activities of four different cell types. We demonstrate how dynamic control of cyclic normoxic-hypoxic cell microenvironments can be readily accomplished using programmable flow profiles employing both gas-impermeable and gas-permeable microfluidic biochips.

Engineering of three-dimensional pre-vascular networks within fibrin hydrogel constructs by microfluidic control over reciprocal cell signaling

Reengineering functional vascular networks in vitro remains an integral part in tissue engineering, since the incorporation of non-perfused tissues results in restricted nutrient supply and limited waste removal. Microfluidic devices are routinely used to mimic both physiological and pathological vascular microenvironments. Current procedures either involve the investigation of growth factor gradients and interstitial flow on endothelial cell sprouting alone or on the heterotypic cell-cell interactions between endothelial and mural cells. However, limited research has been conducted on the influence of flow on co-cultures of these cells. Here, we exploited the ability of microfluidics to create and monitor spatiotemporal gradients to investigate the influence of growth factor supply and elution on vascularization using static as well as indirect and direct flow setups. Co-cultures of human adipose-derived stem/stromal cells and human umbilical vein endothelial cells embedded in fibrin hydrogels were found to be severely affected by diffusion limited growth factor gradients as well as by elution of reciprocal signaling molecules during both static and flow conditions. Static cultures formed pre-vascular networks up to a depth of 4 mm into the construct with subsequent decline due to diffusion limitation. In contrast, indirect flow conditions enhanced endothelial cell sprouting but failed to form vascular networks. Additionally, complete inhibition of pre-vascular network formation was observable for direct application of flow through the hydrogel with decline of endothelial cell viability after seven days. Using finite volume CFD simulations of different sized molecules vital for pre-vascular network formation into and out of the hydrogel constructs, we found that interstitial flow enhances growth factor supply to the cells in the bulk of the chamber but elutes cellular secretome, resulting in truncated, premature vascularization.

Enhanced mid-infrared multi-bounce ATR spectroscopy for online detection of hydrogen peroxide using a supercontinuum laser

A compact multi-bounce attenuated total reflection (ATR) probe combined with a Fabry-Pérot filter spectrometer (FPFS) has been developed for detection of hydrogen peroxide used for oxidative gas scrubbing operating in the mid-infrared (MIR) spectral region. A novel MIR supercontinuum light source is employed to enhance the quantification capabilities of the sensor and is compared to a classical thermal emitter. An improvement of a factor of 4 in noise and approximately a factor of 3 in limit of detection is shown in this study allowing fast inline detection of aqueous hydrogen peroxide solutions around 0.1%.

Production of Micro- and Nanoscale Lignin from Wheat Straw Using Different Precipitation Setups

Micro- and nanosize lignin has recently gained interest due to its improved properties compared to standard lignin available today. As the second most abundant biopolymer after cellulose, lignin is readily available but used for rather low-value applications. Applications for lignin in micro- to nanoscale however, ranging from improvement of mechanical properties of polymer nanocomposites, have bactericidal and antioxidant properties and impregnations to hollow lignin drug carriers for hydrophobic and hydrophilic substances. This research represents a whole biorefinery process chain and compares different precipitation setups to produce submicron lignin particles from lignin containing an organosolv pretreatment extract from wheat straw. A batch precipitation in a stirred vessel was compared with continuous mixing of extract and antisolvent in a T-fitting and mixing in a T-fitting followed by a static mixer. The precipitation in the combination of T-fitting and static mixer with improved precipitation parameters yields the smallest particle size of around 100 nm. Furthermore, drying of particles did not influence the particle sizes negatively by showing decreased particle diameters after the separation process.

A nonchromatographic process for purification of secretory immunoglobulins from caprine whey

Secretory immunoglobulins are an important antibody class being primarily responsible for immunoprotection of mucosal surfaces. A simple, non-chromatographic purification process for secretory immunoglobulins from caprine whey was developed. In the first process step whey was concentrated 30-40-fold on a 500 kDa membrane, thereby increasing the purity from 3% to 15%. The second step consisted of a fractionated PEG precipitation, in which high molecular weight impurities were removed first and in the second stage the secretory immunoglobulins were precipitated, leaving a majority of the low molecular weight proteins in solution. The re-dissolved secretory immunoglobulin fraction had a purity of 43% which could then be increased to 72% by diafiltration at a volume exchange factor of 10. Further increase of purity was only possible at the expense of very high buffer consumption. If diafiltration was performed directly after ultrafiltration, followed by precipitation, the yield was higher but purity was only 54%. Overall, filtration performance was characterized by high concentration polarization, therefore process conditions were set to low trans-membrane pressure and moderate protein concentration. As such purity and to a lesser extent throughput were the major objectives rather than yield, since whey, as a by-product of the dairy industry, is a cheap raw material of almost unlimited supply. Ultra-/diafiltration performance was described well by correlations using dimensionless numbers. Compared with a theoretical model (Graetz/Leveque solution) the flux was slightly overestimated. © 2017 American Institute of Chemical Engineers Biotechnol. Prog., 33:642-653, 2017.

Designing Better Membrane Modules Using CFD

In the last decades, a large number of studies have been carried out on the utilization of membranes in separation processes. However, most of these studies deal with material properties, experimental investigations and process modeling. Only quite a few authors utilized computational fluid dynamics (CFD) to analyze the flow and mass transfer in membrane modules. Using CFD it is possible to obtain spatially resolved information on the behavior of membrane modules, allowing for the investigation of geometric effects on the performance of the module. This includes e. g. the positioning of the permeate outlets, the flow alignment (co- and/or counter-current), the use of spacers and other mixing promoters and also the subject of concentration polarization close to the membrane surface. In our present study we made use of OpenFOAM®, which is a free open sourced CFD toolbox. The toolbox enables for introducing new solver code, membraneFoam, based on the standard multicomponent solver reactingFoam. In membraneFoam suitable source and sink terms have been added to account for trans-membrane flux – in this case based on the solution-diffusion model for glassy polymer gas permeation membranes. The solver has been preliminary validated using literature data obtained from a process simulation code. In a first stage of the research work the positioning of the permeate outlet and the flow alignment have been investigated for a hollow fiber gas permeation module. By adjusting the position of the permeate outlet the shell side flow can be co-current, counter-current or mixed type relative to the retentate flow inside the fibers. Since this influences the driving force for the trans-membrane flux, effects on the module performance are expected which have been analyzed using the described membraneFoam CFD approach.

Simulation of Membrane Gas Separation Process Using Aspen Plus® V8.6

Implementing membrane gas separation systems have led to remarkable profits in both processes and products. This study presents the modeling and simulation of membrane gas separation systems using Aspen Plus® V8.6. A FORTRAN user model and a numerical solution procedure have been developed to characterize asymmetric hollow fiber membrane modules. The main benefit of this model is that it can be easily incorporated into a commercial simulator and used as a unit operation model in complex systems. A comparison between the model and the experimental cases at different operation conditions shows that calculated values are in good agreement with measured values. This model is suitable for future developments as well as design and performance analysis of multicomponent gas permeation systems prior to experimental realization.

Biogas desulfurization and biogas upgrading using a hybrid membrane system--modeling study

Membrane gas permeation using glassy membranes proved to be a suitable method for biogas upgrading and natural gas substitute production on account of low energy consumption and high compactness. Glassy membranes are very effective in the separation of bulk carbon dioxide and water from a methane-containing stream. However, the content of hydrogen sulfide can be lowered only partially. This work employs process modeling based upon the finite difference method to evaluate a hybrid membrane system built of a combination of rubbery and glassy membranes. The former are responsible for the separation of hydrogen sulfide and the latter separate carbon dioxide to produce standard-conform natural gas substitute. The evaluation focuses on the most critical upgrading parameters like achievable gas purity, methane recovery and specific energy consumption. The obtained results indicate that the evaluated hybrid membrane configuration is a potentially efficient system for the biogas processing tasks that do not require high methane recoveries, and allows effective desulfurization for medium and high hydrogen sulfide concentrations without additional process steps.

Design and scale-up of an oxidative scrubbing process for the selective removal of hydrogen sulfide from biogas

Reliable and selective removal of hydrogen sulfide (H(2)S) is an essential part of the biogas upgrading procedure in order to obtain a marketable and competitive natural gas substitute for flexible utilization. A promising biogas desulfurization technology has to ensure high separation efficiency regardless of process conditions or H(2)S load without the use or production of toxic or ecologically harmful substances. Alkaline oxidative scrubbing is an interesting alternative to existing desulfurization technologies and is investigated in this work. In experiments on a stirred tank reactor and a continuous scrubbing column in laboratory-scale, H(2)S was absorbed from a gas stream containing large amounts of carbon dioxide (CO(2)) into an aqueous solution prepared from sodium hydroxide (NaOH), sodium bicarbonate (NaHCO(3)) and hydrogen peroxide (H(2)O(2)). The influence of pH, redox potential and solution aging on the absorption efficiency and the consumption of chemicals was investigated. Because of the irreversible oxidation reactions of dissolved H(2)S with H(2)O(2), high H(2)S removal efficiencies were achieved while the CO(2) absorption was kept low. At an existing biogas upgrading plant an industrial-scale pilot scrubber was constructed, which efficiently desulfurizes 180m(3)/h of raw biogas with an average removal efficiency of 97%, even at relatively high and strongly fluctuating H(2)S contents in the crude gas.

Chemical-oxidative scrubbing for the removal of hydrogen sulphide from raw biogas: potentials and economics

In the present work chemical-oxidative scrubbing as a novel method for the desulphurisation of raw biogas is presented with a special focus on the process potentials and economics. The selective absorption of hydrogen sulphide from gas streams containing high amounts of carbon dioxide using caustic solutions is not trivial but has been treated in literature. However, the application of this method to biogas desulphurisation has not been established so far. Based on rigorous experimental work, an industrial-scale pilot plant has been designed, erected and commissioned at a biogas plant with biogas upgrading and gas grid injection in Austria. Data collected from the 12-month monitored operation has been used to elaborate performance as well as economic parameters for the novel desulphurisation method. The proposed technology offers significant operational advantages regarding the degree of automation and the flexibility towards fluctuations in process boundary conditions. Furthermore, the economic assessment revealed the high competitiveness of the chemical-oxidative scrubbing process compared with other desulphurisation technologies with the named advantageous operational behaviour.

Measuring the Effective Mass Transfer Area of a Structured Packing by a Chemical Method

The effective mass transfer area of a Mellapak 750 Y structured packing was measured in a bench- scale plant with a column having an internal diameter of 100mm, and a packing height of 518 mm, using a broad range of gas and liquid flow rates. The absorption of carbon dioxide into natrium hydroxide aqueous solutions of 0.5 and 1.0 mol/L has been employed as test reaction. The validity of data obtained was tested by checking the two conditions of fast pseudo first order irreversible reaction. The data have been correlated by a criterial equation giving the ratio between the effective and the geometric areas versus the Reynolds number of the liquid phase. The coefficients of the equation have been identified by regression.

CFD methods for the reduction of reactive gas emission from a paper laminating machine

In cooperation with the world's second largest manufacturer of beverage cartons (SIG Combibloc) for liquid foodstuffs an innovative off-take for neutralisation of reactive gas in a paper laminating machine was constructed. A great challenge during engineering work was ensuring a high concentration of the reactive gas where needed and at the same time minimising work place impact in a machine basically without housing. Preliminary 2D-models of the machine geometry proved to be insufficient in describing all the governing flow phenomena. A simplified 3D-geometry containing all important parts of the complex machinery was necessary for accurate predictions. It was found that the driving force of air movement and transport of reactive gas (which acts as an adhesive agent) from the reaction zone in the interior of the laminating machine to the outside is a boundary flow caused by the rapid movement of carton material and rotating cylinders. A physically correct simulation result of the boundary flow is a premise for correct prediction of air flow in and around the machinery. Lacking experimental data (due to an inaccessible geometry) a worst case scenario was constructed by generating a grid and using turbulence models that maximised mass transport in the boundary layer region and thus emission of (tracer)gas from the machine. CFD simulations were done using the geometry preprocessor Gambit, and the finite volume solver Fluent. The results of the analysis of the emission paths from the machine were surprising and led to the construction of an effective off-take relatively far away from the emission source. The chosen position ensures low disturbance of highly sensitive flow patterns inside the machine and diffusive mixing, dilution and contamination of the surroundings. The effect of the new off-take is an immediate and significant rise in air quality in the vicinity of the laminating machine and ensures maximum allowed concentration in the plant area. The product quality furthermore is uncompromised by the working off-take which was another important goal of this work.

Towards biochemical reaction monitoring using FT-IR synchrotron radiation

A lab-on-a-chip device made of CaF2 windows and SU-8 polymer was used for fluid lamination to achieve rapid mixing of two streamlines with a cross section of 300 x 5 microm each. Time resolved measurements of the induced chemical reaction was achieved by applying constant feeding low flow rates and by on-chip measurement at defined distances after the mixing point. Synchrotron IR microscopic detection was employed for direct and label-free monitoring of (bio)chemical reactions. Furthermore, using synchrotron IR microscopy the measurement spot could be reduced to the diffraction limit, thus maximizing time resolution in the experimental set-up under study. Based on computational fluid dynamic simulations the principle of the set-up is discussed. Experimental results on the basic hydrolysis of methyl chloroacetate proved the working principle of the experimental set-up. First results on the interaction between the antibiotic vancomycin and a tripeptide (Ac2KAA) involved in the build up of the membrane proteins of gram-positive bacteria are presented.