Ferrous iron oxidation by foam immobilized Acidithiobacillus ferrooxidans: Experiments and modeling.

Ferrous iron bio-oxidation by Acidithiobacillus ferrooxidans immobilized on polyurethane foam was investigated. Cells were immobilized on foams by placing them in a growth environment and fully bacterially activated polyurethane foams (BAPUFs) were prepared by serial subculturing in batches with partially bacterially activated foam (pBAPUFs). The dependence of foam density on cell immobilization process, the effect of pH and BAPUF loading on ferrous oxidation were studied to choose operating parameters for continuous operations. With an objective to have high cell densities both in foam and the liquid phase, pretreated foams of density 50 kg/m(3) as cell support and ferrous oxidation at pH 1.5 to moderate the ferric precipitation were preferred. A novel basket-type bioreactor for continuous ferrous iron oxidation, which features a multiple effect of stirred tank in combination with recirculation, was designed and operated. The results were compared with that of a free cell and a sheet-type foam immobilized reactors. A fivefold increase in ferric iron productivity at 33.02 g/h/L of free volume in foam was achieved using basket-type bioreactor when compared to a free cell continuous system. A mathematical model for ferrous iron oxidation by Acidithiobacillus ferrooxidans cells immobilized on polyurethane foam was developed with cell growth in foam accounted by an effectiveness factor. The basic parameters of simulation were estimated using the experimental data on free cell growth as well as from cell attachment to foam under nongrowing conditions. The model predicted the phase of both oxidation of ferrous in shake flasks by pBAPUFs as well as by fully activated BAPUFs for different cell loadings in foam. Model for stirred tank basket bioreactor predicted within 5% both transient and steady state of the experiments closely for the simulated dilution rates. Bio-oxidation at high Fe(2+) concentrations were simulated with experiments when substrate and product inhibition coefficients were factored into cell growth kinetics.

Soft-particle model analysis of effect of LPS on electrophoretic softness of Acidithiobacillus ferrooxidans grown in presence of different metal ions.

The effect of surface lipopolysaccharides (LPS) on the electrophoretic softness and fixed charge density in the ion-penetrable layer of Acidithiobacillus ferrooxidans cells grown in presence of copper or arsenic ions have been discussed. The electrophoretic mobility data were analyzed using the soft-particle electrophoresis theory. Cell surface potentials of all the strains based on soft-particle theory were lower than those estimated using the conventional Smoluchowski theory. Exposure to metal ions increased the surface electrophoretic softness with decrease in the fixed charge density. Effect of cell surface lipopolysaccharides on the model parameters are investigated and discussed.

Mathematical model for evaluation of mass transfer limitations in phenol biodegradation by immobilized Pseudomonas putida.

A mathematical model is proposed to analyze the mass transfer limitations in phenol biodegradation using Pseudomonas putida immobilized in calcium alginate. The model takes into account internal and external mass transfer limitations, substrate inhibition kinetics and the dependence of the effective diffusivity of phenol in alginate gel on cell concentration. The model is validated with the experimental data from batch fermentation. The effect of various operating conditions such as initial phenol concentration, initial cell loading, alginate gel loading on the biodegradation of phenol is experimentally demonstrated. Phenol degradation time is found to decrease initially and reach stationary value with increase in cell loading as well as gel loading. The model predicts these trends reasonably well and shows the presence of external mass transfer limitations. A new concept of effectiveness factor is introduced to analyze the overall performance of batch fermentation.

Surface chemical studies of Thiobacillus ferrooxidans with reference to copper tolerance.

A strain of Thiobacillus ferrooxidans was adapted to grow at higher concentrations of copper by single step culturing in the presence of 20 g/L (0.314 mol/L) cupric ions added to 9K medium. Exposure to copper results in change in the surface chemistry of the microorganism. The isoelectric point of the adapted strain (pI = 4.7) was observed to be at a higher pH than that of the wild unadapted strain (pI = 2.0). Compared to the wild strain, the copper adapted strain was found to be more hydrophobic and showed enhanced attachment efficiency to the pyrite mineral. The copper adsorption ability of the adapted strain was also found to be higher than that of the wild strain. Fourier transform infrared spectroscopy of adapted cells suggested that a proteinaceous new cell surface component is synthesized by the adapted strain. Treatment of adapted cells with proteinase-K, resulted in complete loss of tolerance to copper, reduction in copper adsorption and hydrophobicity of the adopted cells. These observations strongly suggest a role played by cell surface modifications of Thiobacillus ferrooxidans in imparting the copper tolerance to the cells and bioleaching of sulphide minerals.

Dissolution of sulphur particles by Thiobacillus ferrooxidans: substrate for unattached cells.

The growth of Thiobacillus ferrooxidans on sulphur is known to proceed through the attachment of cells to the sulphur particles. Experiments, However, show that the cells in the liquid phase, which are not attached to the sulphur particles, also grow. It has been shown through the use of a two-compartment membrane reactor that this increase is partially due to the release of ions, corresponding to partially oxidized of sulphur, into the solution by the attached cells. The main soluble ion has been found to the thiosulphate, but traces of sulphite have also been detected.

Optimization of biphasic growth of Saccharomyces carlsbergensis in fed-batch culture.

The optimal glucose feeding policy for the fed-batch culture of Saccharomyces carlsbergensis is presented. The biphasic nature of growth results in a singular feed rate policy that is unique to this organism. When the operating cost is high, the reduction in operating time forces the cells to utilize both glucose and ethanol toward the end of fermentation time and results in a decreasing rate of glucose addition, unlike the normally observed increasing feed rate. The optimal feeding policy depends heavily on the initial conditions and is highly sensitive to changes in kinetic parameters. A semiempirical scheme for feedback optimization is suggested for the fed-batch yeast culture.

Simple nonsingular control approach to fed-batch fermentation optimization.

Determination of the optimal feed rate for fed-batch fermentation is normally a problem in singular control with a state inequality constraint and as such is, in general, difficult to solve, especially for those described by a large number of dynamic mass balance equations. In this article we use a new set of state variables and the culture volume as the control variable. In this way the problem is converted to one of nonsingular control with the magnitude and rate constraints on the manipulated variable and can be numerically solved by a gradient-based technique, thus avoiding the difficulty associated with singular control problems. Examples are given to illustrate the method.

Feedback optimization of fed-batch fermentation.

The problem of feedback optimization of the feed rate for fed-batch fermentation processes is formulated in the framework of singular control theory and switching hypersurfaces. Using four differential balance equations that describe a general class of fedbatch processes and a general objective function to be minimized, it is shown that under certain restrictions the feedback optimization of the feed rate can be realized as a nonlinear function of the state variables, such as the concentrations of cell mass, substrate and product, and the fermentor volume. The restrictions on the initial conditions, the fermentation kinetics and the objective function, that are needed for realization of the feedback optimization, are provided. Fed-batch fermentation models of lysine and alcohol are used to construct switching curves and to illustrate the feedback optimization of the feed flow rates.

Analysis of continuous cultures of recombinant methylotrophs.

Static and dynamic characteristics of continuous cultures of recombinant methylotrophs, which are designed to improve the selectivity of plasmid-bearing cells and the plasmid stability, are investigated in detail. Operational regions in which coexistence (survival of plasmid-bearing and plasmid-free cells) operation is feasible have been identified in the entire space of kinetic parameters and operating variables. The stability characteristics of each steady state are examined. The existence of oscillatory states around the coexistence steady state is investigated using the dynamic (Hopf) bifurcation analysis. For proper startup of the continuous culture operation, it is critical to identify the sets of initial conditions, if any, which lead to transients that ultimately result in washout of plasmid-bearing cells and avoid such conditions. For the numerical illustrations presented, the coexistence steady state happens to be locally stable over much of its region of existence, particular for the operating conditions corresponding to maximum productivity.

General characteristics of optimal feed rate profiles for various fed-batch fermentation processes.

General Characteristics of the optimal feed rate profiles have been deduced for various fed-batch fermentation processes by analyzing singular controls and singular arcs. The optimal control sequences depend on the shapes of the specific growth and product formation rates, mu andpi, and the initial conditions. For fed-batch processes described by four mass balance equations, the most general optimal control sequence consists of a period of maximum feed rate, a period of minimum feed rate (a batch period), a period of singular feed rate (variable and intermediate), and a batch period. Degenerate sequences in which one or more periods are missing can result with a particular set of initial conditions. If the fermentation time is not critical, the singular control maximizes the net yield of product and only when the time is also important, it balances a trade off between the yield of product and the specific growth rate which dictates the fermentation time. With the sequence of optimal control known, the optimal feed rate profile determination is reduced to a problem of determining switching times.

Computational algorithms for optimal feed rates for a class of fed-batch fermentation: Numerical results for penicillin and cell mass production.

Based upon the general characteristics of the optimal feed rate profiles presented in an earlier article, efficient computational algorithms have been developed for fed-batch fermentation processes described by four or less mass balance equations. These algorithms make computations of optimal substrate feed rate profiles straight forward and simple for various fed-batch cultures for such products as antibiotics, amino acids, enzymes, alcohols, and cell mass. Numerical examples of penicillin fermentation and bacterial cell mass production are given in detail, illustrating the use of these algorithms.