Wall-Immobilized Biocatalyst vs. Packed Bed in Miniaturized Continuous Reactors: Performances and Scale-Up.

Sustainable biocatalysis syntheses have gained considerable popularity over the years. However, further optimizations - notably to reduce costs - are required if the methods are to be successfully deployed in a range of areas. As part of this drive, various enzyme immobilization strategies have been studied, alongside process intensification from batch to continuous production. The flow bioreactor portfolio mainly ranges between packed bed reactors and wall-immobilized enzyme miniaturized reactors. Because of their simplicity, packed bed reactors are the most frequently encountered at lab-scale. However, at industrial scale, the growing pressure drop induced by the increase in equipment size hampers their implementation for some applications. Wall-immobilized miniaturized reactors require less pumping power, but a new problem arises due to their reduced enzyme-loading capacity. This review starts with a presentation of the current technology portfolio and a reminder of the metrics to be applied with flow bioreactors. Then, a benchmarking of the most recent relevant works is presented. The scale-up perspectives of the various options are presented in detail, highlighting key features of industrial requirements. One of the main objectives of this review is to clarify the strategies on which future study should center to maximize the performance of wall-immobilized enzyme reactors.

Nitrilase immobilization and transposition from a micro-scale batch to a continuous process increase the nicotinic acid productivity.

In recent years, many biocatalytic processes have been developed for the production of chemicals and pharmaceuticals. In this context, enzyme immobilization methods have attracted attention for their advantages, such as continuous production and increased stability. Here, enzyme immobilization methods and a collection of nitrilases from biodiversity for the conversion of 3-cyanopyridine to nicotinic acid were screened. Substrate conversion over 10 conversion cycles was monitored to optimize the process. The best immobilization conditions were found with cross-linking using glutaraldehyde to modify the PMMA beads. This method showed good activity over 10 cycles in a batch reactor at 30 and 40°C. Finally, production with a new thermostable nitrilase was examined in a continuous packed bed reactor, showing very high stability of the biocatalytic process at a flow rate of 0.12 ml min-1 and a temperature of 50°C. The complete conversion of 3-cyanopyridine was obtained over 30 days of operation. Future steps will concern reactor scale-up to increase the production rate with reasonable pressure drops.

H2 production by photofermentation in an innovative plate-type photobioreactor with meandering channels.

Hydrogen production by Rhodobacter capsulatus is an anaerobic, photobiological process requiring specific mixing conditions. In this study, an innovative design of a photobioreactor is proposed. The design is based on a plate-type photobioreactor with an interconnected meandering channel to allow culture mixing and H2 degassing. The culture flow was characterized as a quasi-plug-flow with radial mixing caused by a turbulent-like regime achieved at a low Reynolds number. The dissipated volumetric power was decreased 10-fold while maintaining PBR performances (production and yields) when compared with a magnetically stirred tank reactor. To increase hydrogen production flow rate, several bacterial concentrations were tested by increasing the glutamate concentration using fed-batch cultures. The maximum hydrogen production flow rate (157.7 ± 9.3 ml H2 /L/h) achieved is one of the highest values so far reported for H2 production by R. capsulatus. These first results are encouraging for future scale-up of the plate-type reactor.