Mitchell / Krieger / Berovic Solid-State Fermentation Bioreactors

Fundamentals of Design and Operation
1. Auflage 2006
ISBN: 978-3-540-31286-4
Verlag: Springer Berlin Heidelberg
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 448 Seiten

This concise professional reference provides a fundamental framework for the design and operation of solid-state fermentation bioreactors, enabling researchers currently working at laboratory scale to scale up their processes. The authors survey bioreactor types in common use, and describe in depth how to plan a project, and model heat transfer phenomena. The book includes case studies, and a review of practical issues involved in bioreactor performance.

Autoren/Hrsg.

Mitchell, David A.

Krieger, Nadia

Berovic, Marin

Inhaltsverzeichnis

1;Preface;5
2;Acknowledgements;7
3;Contents;10
4;1 Solid-State Fermentation Bioreactor Fundamentals: Introduction and Overview;38
4.1;1.1 What Is “Solid-State Fermentation”?;38
4.2;1.2 Why Should We Be Interested in SSF?;40
4.3;1.3 What Are the Current and Potential Applications of SSF?;42
4.4;1.4 Why Do We Need a Book on the Fundamentals of SSF Bioreactors?;43
4.5;1.5 How Is this Book Organized?;45
5;2 The Bioreactor Step of SSF: A Complex Interaction of Phenomena;50
5.1;2.1 The Need for a Qualitative Understanding of SSF;50
5.2;2.2 The General Steps of an SSF Process;51
5.3;2.3 The Bioreactor Step of an SSF Process;53
5.4;2.4 The Physical Structure of SSF Bioreactor Systems;54
5.4.1;2.4.1 A Macroscale View of the Phases in an SSF Bioreactor;54
5.4.2;2.4.2 A Microscale Snapshot of the Substrate Bed;57
5.5;2.5 A Dynamic View of the Processes Occurring;59
5.5.1;2.5.1 A Dynamic View with a Time Scale of Seconds to Minutes;59
5.5.2;2.5.2 A Dynamic View with a Time Scale of Hours to Days;61
5.6;2.6 Where Has this Description Led Us?;68
5.7;Further Reading;69
6;3 Introduction to Solid-State Fermentation Bioreactors;70
6.1;3.1 Introduction;70
6.2;3.2 Bioreactor Selection and Design: General Questions;71
6.2.1;3.2.1 The Crucial Questions;72
6.2.2;3.2.2 Other Questions to Consider;73
6.3;3.3 Overview of Bioreactor Types;75
6.3.1;3.3.1 Basic Design Features of the Various Bioreactor Types;75
6.3.2;3.3.2 Overview of Operating Variables;77
6.4;3.4 A Guide for Bioreactor Selection;78
6.5;Further Reading;80
7;4 Basics of Heat and Mass Transfer in Solid-State Fermentation Bioreactors;82
7.1;4.1 Introduction;82
7.2;4.2 An Overall Balance Over the Bioreactor;82
7.3;4.3 Looking Within the Bioreactor in More Detail;84
7.3.1;4.3.1 Phenomena Within Subsystems Within the Bioreactor;84
7.3.2;4.3.2 Transfer Between Subsystems When the Substrate Bed Is Treated as a Single Pseudo- Homogeneous Phase;87
7.3.3;4.3.3 Transfer Between Subsystems When the Substrate Bed Is Treated as Two Separate Phases;88
7.3.4;4.3.4 Bulk Gas Flow Patterns and Pressure Drops;90
7.3.5;4.3.5 Mixing Patterns in Agitated Beds of Solids;93
7.4;Further Reading;93
8;5 The Scale-up Challenge for SSF Bioreactors;94
8.1;5.1 Introduction;94
8.2;5.2 The Challenges Faced at Large Scale in SLF and SSF;94
8.3;5.3 The Reason Why Scale-up Is not Simple;95
8.4;5.4 Approaches to Scale-up of SSF Bioreactors;100
8.5;Further Reading;101
9;6 Group I Bioreactors: Unaerated and Unmixed;102
9.1;6.1 Basic Features, Design, and Operating Variables for Tray- type Bioreactors;102
9.2;6.2 Use of Bag Systems in Modern Processes;103
9.3;6.3 Heat and Mass Transfer in Tray Bioreactors;104
9.3.1;6.3.1 Oxygen Profiles Within Trays;104
9.3.2;6.3.2 Temperature Profiles Within Trays;106
9.3.3;6.3.3 Insights from Dynamic Modeling of Trays;108
9.4;6.4 Conclusions;112
9.5;Further Reading;113
10;7 Group II Bioreactors: Forcefully-Aerated Bioreactors Without Mixing;114
10.1;7.1 Introduction;114
10.2;7.2 Basic Features, Design, and Operating Variables for Packed- Bed Bioreactors;114
10.3;7.3 Experimental Insights into Packed-Bed Operation;118
10.3.1;7.3.1 Large-Scale Packed-Beds;119
10.3.2;7.3.2 Pilot-Scale Packed-Beds;120
10.3.3;7.3.3 Laboratory-Scale Packed-Beds;121
10.4;7.4 Conclusions on Packed-Bed Bioreactors;130
10.5;Further Reading;131
11;8 Group III: Rotating-Drum and Stirred-Drum Bioreactors;132
11.1;8.1 Introduction;132
11.2;8.2 Basic Features, Design, and Operating Variables for Group III Bioreactors;132
11.3;8.3 Experimental Insights into the Operation of Group III Bioreactors;135
11.4;8.4 Insights into Mixing and Transport Phenomena in Group III Bioreactors;141
11.5;8.5 Conclusions on Rotating-Drum and Stirred-Drum Bioreactors;149
12;9 Group IVa: Continuously-Mixed, Forcefully- Aerated Bioreactors;152
12.1;9.1 Introduction;152
12.2;9.2 Basic Features, Design, and Operating Variables of Group IVa Bioreactors;152
12.3;9.3 Where Continuously-Agitated, Forcefully-Aerated Bioreactors Have Been Used;154
12.4;9.4 Insights into Mixing and Transport Phenomena in Group IVa Bioreactors;162
12.5;9.5 Conclusions on Group IVa Bioreactors;165
13;10 Group IVb: Intermittently-Mixed Forcefully- Aerated Bioreactors;166
13.1;10.1 Introduction;166
13.2;10.2 Basic Features of Group IVb Bioreactors;166
13.3;10.3 Experimental Insights into the Performance of Group IVb Bioreactors;168
13.4;10.4 Insights into Mixing and Transport Phenomena in Group IVb Bioreactors;175
13.5;10.5 Conclusions on Group IVb Bioreactors;177
14;11 Continuous Solid-State Fermentation Bioreactors;178
14.1;11.1 Introduction;178
14.2;11.2 Basic Features of Continuous SSF Bioreactors;178
14.2.1;11.2.1 Equipment;178
14.2.2;11.2.2 Flow Patterns: Real-Flow Models;183
14.3;11.3 Continuous Versus Batch Mode of Operation;185
14.3.1;11.3.1 Reduction of Upstream and Downstream Investment;185
14.3.2;11.3.2 Uniformity of the Product from Batch and Continuous Bioreactors;186
14.3.3;11.3.3 Enhanced Production Rates;187
14.3.4;11.3.4 Contamination;187
14.4;11.4 Comparison by Simulation of the Three CSSFBs;189
14.4.1;11.4.1 Continuous Tubular Flow Bioreactors (CTFBs) with Recycling;189
14.4.2;11.4.2 Continuous Rotating Drum Bioreactor (CRDB);191
14.4.3;11.4.3 Continuous Stirred Tank Bioreactor (CSTB);192
14.4.4;11.4.4 Evaluation of the Various CSSFB Configurations;193
14.5;11.5 Scientific and Technical Challenges for CSSFBs;195
14.6;Further Reading;195
15;12 Approaches to Modeling SSF Bioreactors;196
15.1;12.1 What Are Models and Why Model SSF Bioreactors?;196
15.2;12.2 Using Models to Design and Optimize an SSF Bioreactor;198
15.3;12.3 The Anatomy of a Model;201
15.4;12.4 The Seven Steps of Developing a Bioreactor Model;204
16;13 Appropriate Levels of Complexity for Modeling SSF Bioreactors;216
16.1;13.1 What Level of Complexity Should We Aim for in an SSF Bioreactor Model?;216
16.2;13.2 What Level of Detail Should Be Used to Describe the Growth Kinetics?;216
16.2.1;13.2.1 Growth Should Be Treated as Depending on Which Factors?;217
16.2.2;13.2.2 Is It Worthwhile to Describe the Spatial Distribution of the Biomass at the Microscale?;219
16.2.3;13.2.3 Typical Features of the Kinetic Sub-models;220
16.3;13.3 What Level of Detail Should Be Used to Describe Transport Processes?;220
16.4;13.4 At the Moment Fast-Solving Models Are Useful;222
16.5;13.5 Having Decided on Fast-Solving Models, How to Solve Them?;225
16.6;13.6 Conclusions;225
16.7;Further Reading;226
17;14 The Kinetic Sub-model of SSF Bioreactor Models: General Considerations;228
17.1;14.1 What Is the Aim of the Kinetic Analysis?;228
17.2;14.2 How Will Growth Be Measured Experimentally?;231
17.2.1;14.2.1. The Problem of Measuring Biomass in SSF;231
17.2.2;14.2.2 Indirect Approaches to Monitoring Growth;233
17.3;14.3 What Units Should Be Used for the Biomass?;234
17.3.1;14.3.1 Grams of Biomass per Gram of Fresh Sample;236
17.3.2;14.3.2 Grams of Biomass per Gram of Dry Sample;236
17.3.3;14.3.3 Grams of Biomass per Gram of Initial Fresh or Dry Sample;237
17.3.4;14.3.4 Which Set of Units Is Best to Use for Expressing the Biomass?;238
17.4;14.4 Kinetic Profiles and Appropriate Equations;238
17.5;14.5 Conclusions;241
17.6;Further Reading;242
18;15 Growth Kinetics in SSF Systems: Experimental Approaches;244
18.1;15.1 Experimental Systems for Studying Kinetics;244
18.1.1;15.1.1. Flasks in an Incubator;245
18.1.2;15.1.2. Columns in a Waterbath;247
18.1.3;15.1.3. Comparison of the Two Systems;248
18.2;15.2 Experimental Planning;248
18.3;15.3 Estimation of Biomass from Measurements of Biomass Components;251
18.3.1;15.3.1 Suitable Systems for Undertaking Calibration Studies;251
18.3.2;15.3.2 Conversion of Measurements of Components of the Biomass;253
18.3.3;15.3.3 Limitations of these Calibration Methods;254
18.4;15.4 Conclusion;254
18.5;Further Reading;254
19;16 Basic Features of the Kinetic Sub-model;256
19.1;16.1 The Kinetic Sub-model Is Based on a Differential Growth Equation;256
19.2;16.2 The Basic Kinetic Expression;257
19.3;16.3 Incorporating the Effect of the Environment on Growth;259
19.3.1;16.3.1 Incorporating the Effect of Temperature on Growth;262
19.3.2;16.3.2 Incorporating the Effect of Water Activity on Growth;265
19.3.3;16.3.3 Combining the Effects of Several Variables;267
19.4;16.4 Modeling Death Kinetics;268
19.4.1;16.4.1 General Considerations in Modeling of Death Kinetics;268
19.4.2;16.4.2 Approaches to Modeling Death Kinetics that Have Been Used;269
19.5;16.5 Conclusion;271
19.6;Further Reading;271
20;17 Modeling of the Effects of Growth on the Local Environment;272
20.1;17.1 Introduction;272
20.2;17.2 Terms for Heat, Water, Nutrients, and Gases;274
20.2.1;17.2.1 Metabolic Heat Production;274
20.2.2;17.2.2 Water Production;275
20.2.3;17.2.3 Substrate and Nutrient Consumption;275
20.2.4;17.2.4 Oxygen Consumption and Carbon Dioxide Production;276
20.2.5;17.2.5 General Considerations with Respect to Equations for the Effects of Growth on the Environment;280
20.3;17.3 Modeling Particle Size Changes;281
20.3.1;17.3.1 An Empirical Equation for Particle Size Reduction;281
20.3.2;17.3.2 How to Model Particle Size Changes in Bioreactor Models?;282
20.4;17.4 Product Formation – Empirical Approaches;283
20.5;17.5 Conclusions;284
20.6;Further Reading;284
21;18 Modeling of Heat and Mass Transfer in SSF Bioreactors;286
21.1;18.1 Introduction;286
21.2;18.2 General Forms of Balance Equations;286
21.3;18.3 Conduction;289
21.4;18.4 Convection;292
21.5;18.5 Evaporation;296
21.6;18.6 Conclusions;300
22;19 Substrate, Air, and Thermodynamic Parameters for SSF Bioreactor Models;302
22.1;19.1 Introduction;302
22.2;19.2 Substrate Properties;302
22.3;19.3 Air Density;310
22.4;19.4 Thermodynamic Properties;311
23;20 Estimation of Transfer Coefficients for SSF Bioreactors;316
23.1;20.1 Introduction;316
23.2;20.2 Thermal Conductivities of Substrate Beds;316
23.3;20.3 Heat Transfer Coefficients Involving the Wall;317
23.4;20.4 Solids-to-Air Heat and Mass Transfer Coefficients Within Beds;320
23.5;20.5 Bed-to-Headspace Transfer Coefficients;321
23.6;20.6 Conclusions;326
23.7;Further Reading;326
24;21 Bioreactor Modeling Case Studies: Overview;328
24.1;21.1 What Can the Models Be Used to Do?;328
24.2;21.2 Limitations of the Models;329
24.3;21.3 The Amount of Detail Provided about Model Development;330
24.4;21.4 The Order of the Case Studies;331
25;22 A Model of a Well-mixed SSF Bioreactor;332
25.1;22.1 Introduction;332
25.2;22.2 Synopsis of the Model;332
25.2.1;22.2.1 The System, Equations, and Assumptions;332
25.2.2;22.2.2 Values of Parameters and Variables;338
25.3;22.3 Insights the Model Gives into the Operation of Well- Mixed Bioreactors;340
25.3.1;22.3.1 Insights into Operation at Laboratory Scale;340
25.3.2;22.3.2 Insights into Operation at Large Scale;344
25.3.3;22.3.3 Effect of Scale and Operation on Contributions to Cooling of the Solids;347
25.4;22.4 Conclusions on the Operation of Well-Mixed Bioreactors;349
25.5;Further Reading;351
26;23 A Model of a Rotating-Drum Bioreactor;352
26.1;23.1 Introduction;352
26.2;23.2 A Model of a Well-Mixed Rotating-Drum Bioreactor;352
26.2.1;23.2.1 Synopsis of the Mathematical Model and its Solution;352
26.3;SURROUNDINGS (;353
26.4;HEADSPACE;353
26.5;(;353
26.6;BED (;353
26.7;HEADSPACE;354
26.8;BED;354
26.9;SURROUNDINGS;354
26.9.1;23.2.2 Predictions about Operation at Laboratory Scale;357
26.9.2;23.2.3 Scale-up of Well-Mixed Rotating-Drum Bioreactors;362
26.10;23.3 What Modeling Work Says about Rotating-Drum Bioreactors Without Axial Mixing;365
26.11;23.4 Conclusions on the Design and Operation of Rotating- Drum Bioreactors;366
26.12;Further reading;367
27;24 Models of Packed-Bed Bioreactors;368
27.1;24.1 Introduction;368
27.2;24.2 A Model of a Traditional Packed-Bed Bioreactor;368
27.2.1;24.2.1 Synopsis of the Mathematical Model and its Solution;370
27.2.2;24.2.2 Base-Case Predictions;371
27.2.3;24.2.3 Insights that Modeling Has Given into Optimal Design and Operation of Traditional Packed- Beds;373
27.3;24.3 A Model of the Zymotis Packed-Bed Bioreactor;378
27.3.1;24.3.1 The Model;378
27.3.2;24.3.2 Insights into Optimal Design and Operation of Zymotis Packed- Beds;379
27.4;24.4 Conclusions on Packed-Bed Bioreactors;384
27.5;Further Reading;384
28;25 A Model of an Intermittently-Mixed Forcefully- Aerated Bioreactor;386
28.1;25.1 Introduction;386
28.2;25.2 Synopsis of the Model;386
28.3;25.3 Insights the Model Gives into Operation of Intermittently- Mixed Bioreactors;390
28.3.1;25.3.1 Predictions about Operation at Laboratory Scale;390
28.3.2;25.3.2 Investigation of the Design and Operation of Intermittently- Mixed Forcefully- Aerated Bioreactors at Large Scale;394
28.4;25.4. Conclusions on Intermittently-Mixed Forcefully- Aerated Bioreactors;397
28.5;Further Reading;399
29;26 Instrumentation for Monitoring SSF Bioreactors;400
29.1;26.1 Why Is It Important to Monitor SSF Bioreactors?;400
29.2;26.2 Which Variables Would We Like to Measure?;400
29.3;26.3 Available Instrumentation for On-line Measurements;402
29.4;26.4 Data Filtering;406
29.4.1;Controllable;407
29.4.2;noise;407
29.4.3;Process;407
29.4.4;noise;407
29.4.5;Electric;407
29.4.6;noise;407
29.4.7;Measurement;407
29.4.8;noise;407
29.4.9;NOISE CLASSIFICATION;407
29.5;26.5 How to Measure the Other Variables?;408
29.6;Further Reading;411
30;27 Fundamentals of Process Control;412
30.1;27.1 Main Ideas Underlying Process Control;412
30.1.1;27.1.1 Feedback;412
30.1.2;27.1.2 Control Loop;413
30.1.3;7.1.3 Computer Control Loop;413
30.2;27.2 Conventional Control Algorithms;414
30.2.1;27.2.1 On/Off Control;414
30.2.2;27.2.2 PID Control;417
30.2.3;27.2.3 Model Predictive Control;422
30.3;Further Reading;423
31;Appendix: Guide to the Bioreactor Programs;464
31.1;A.1 Disclaimer;464
31.2;A.2 General Information and Advice;464
31.3;A.3 Use of the Well-Mixed Bioreactor Model;466
31.4;A.4 Use of the Rotating-Drum Bioreactor Model;468
31.5;A.5 Use of the Traditional Packed-Bed Bioreactor Model;470
31.6;A.6 Use of the Zymotis Packed-Bed Bioreactor Model;471
31.7;A.7 Use of the Model of an Intermittently-Mixed Forcefully- Aerated Bioreactor;474
32;Index;477