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At least 19 records

Bioreactors: Design, Background, and Applications

A bioreactor is any reaction vessel designed to contain a biological reaction with the aims of either growing an organism, producing a biological product, bioremediating waste, or investigating the workings of a biological process within a controlled environment. Bioreactors compose a broad category of useful and ubiquitous technologies present throughout the bioeconomy, which are inherently “dualuse” technologies: holding both immense potential for both benefit and harm to society. Due to this duality, national security professionals must bridge technological understanding and policy acumen to understand how bioreactors are integrated into both, many peaceful applications throughout the global bioeconomy such as in developing or manufacturing life-saving pharmaceuticals, as well as potentially harmful and/or illicit uses, such as producing biowarfare agent. The following document gives a surface-level introduction into this broad category of technology. The first two sections of this document describe the historical origins, then typical contemporary uses of bioreactors as a critical component of the modern bioeconomy providing examples for each use case. The following two sections begin to give a technical description of bioreactor technology introducing the features commonly found in simple bioreactors and providing a non-exhaustive framework for categorizing bioreactors commonly found in wet-microbiology applications. The last two sections present two short discussions on the challenges facing modern bioreactor technology, firstly from a technical standpoint, and then from the non-technical standpoint with special attention to the dual-use dilemma and issue of responsible technological development inherent in most biotechnology.

59 BASIC BIOLOGICAL SCIENCES↗

Anaerobic Dynamic Membrane Bioreactor Development to Facilitate Organic Waste Conversion to Medium-Chain Carboxylic Acids and Their Downstream Recovery

Platform chemicals such as medium-chain carboxylic acids (MCCAs) can be produced from organic waste streams via chain elongation in anaerobic mixed-culture bioreactors. A product recovery system is needed to collect MCCAs from the bioreactor effluent. Membrane-based liquid–liquid extraction, the most commonly used product recovery approach, requires suspended solids removal from the bioreactor effluent to avoid membrane fouling. An anaerobic dynamic membrane bioreactor (AnDMBR) was developed to evaluate MCCA production from brewery and prefermented food waste and to produce a permeate with low suspended solids to facilitate downstream product recovery. The AnDMBR employed an inexpensive stainless-steel mesh as the support material for the development of a biofilm or dynamic membrane, which was responsible for solids–liquid separation. The AnDMBR produced a permeate quality with an average total suspended solids (TSS) concentration of 0.12 g L –1 , while the average bioreactor TSS concentration was two orders of magnitude higher (21.6 g L –1 ). A maximum solids removal efficiency of ≥99% was achieved and good permeate quality was sustained for over 200 days without fouling control or cleaning the support material. In addition to solids–liquid separation, the dynamic membrane was responsible for a substantial fraction of the biological activity of the AnDMBR. The relative activity of Clostridiales, as determined by 16S rRNA sequencing, correlated with MCCA production and was higher in the dynamic membrane (20.0 ± 4.9%) than in the suspended biomass (5.2 ± 2.7%) in the bioreactor. This observation was consistent with MCCA production data as the permeate MCCA concentrations were significantly (p = 8.2 × 10 –5 ) higher than that in the bioreactor, suggesting that the dynamic membrane biofilm contributed to chain elongation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Stacked membrane bioreactor

Scalable biomaterial-based bioreactors are described. In one embodiment, the bioreactor may comprise perforated plates stacked such that the assembled bioreactor has the necessary manifolds and chambers to transport gas and liquids to a biomaterial contained within the bioreactor, and to remove the reaction products. In another embodiment, single use bioreactors are described. Methods of operating the bioreactors are also described.

Abdullah, Zia↗

A perfused multi-well bioreactor platform to assess tumor organoid response to a chemotherapeutic gradient

There is an urgent need to develop new therapies for colorectal cancer that has metastasized to the liver and, more fundamentally, to develop improved preclinical platforms of colorectal cancer liver metastases (CRCLM) to screen therapies for efficacy. To this end, we developed a multi-well perfusable bioreactor capable of monitoring CRCLM patient-derived organoid response to a chemotherapeutic gradient. CRCLM patient-derived organoids were cultured in the multi-well bioreactor for 7 days and the subsequently established gradient in 5-fluorouracil (5-FU) concentration resulted in a lower IC 50 in the region near the perfusion channel versus the region far from the channel. We compared behaviour of organoids in this platform to two commonly used PDO culture models: organoids in media and organoids in a static (no perfusion) hydrogel. The bioreactor IC 50 values were significantly higher than IC 50 values for organoids cultured in media whereas only the IC 50 for organoids far from the channel were significantly different than organoids cultured in the static hydrogel condition. Using finite element simulations, we showed that the total dose delivered, calculated using area under the curve (AUC) was similar between platforms, however normalized viability was lower for the organoid in media condition than in the static gel and bioreactor. Our results highlight the utility of our multi-well bioreactor for studying organoid response to chemical gradients and demonstrate that comparing drug response across these different platforms is nontrivial.

59 BASIC BIOLOGICAL SCIENCES↗

Unraveling the ecological success of Iodidimonas in a bioreactor treating oil and gas produced water

Iodidimonas sp., a bacterium found in bioreactors treating oil and gas produced water as well as iodide-rich brines, has garnered attention for its unique ability to oxidize iodine. However, little is known about the metabolic capabilities that enable Iodidimonas sp. to thrive in certain unique ecological niches. In this study, we isolated, characterized, and sequenced three strains belonging to the Iodidimonas genus from the sludge of a membrane bioreactor used for produced water treatment. We investigated the genomic features of these isolates and compared them with the four publicly available isolate genomes from this genus, as well as a metagenome-assembled genome from the source bioreactor. Our Iodidimonas isolates had several genes associated with mitigating salinity, heavy metal, and organic compound stress, which likely help these bacteria to survive in produced water. Phenotyping tests revealed that while the isolates could utilize a wide variety of simple carbon substrates, they failed to degrade aliphatic or aromatic hydrocarbons, consistent with the lack of genes associated with common hydrocarbon degradation pathways in their genomes. We hypothesize that these microbes may lead a scavenging lifestyle in the bioreactor and similar iodide-rich brines. IMPORTANCE: Occupying a niche habitat and having few representative isolates, the genus Iodidimonas is a relatively understudied alphaproteobacterial group. Its ability to corrode pipes in iodine production facilities has economic implications, and its ability to generate potentially carcinogenic iodinated organic compounds during treatment of oil and gas produced water may cause environmental and health concerns with the recycling of treated water. Therefore, detailed characterization of the metabolic potential of the Iodidimonas isolates in this study both sheds light on their adaptation to the environmental conditions they inhabit and has environmental and economic significance.

Acharya, Shwetha M↗

Genome reduction improves octanoic acid production in scale down bioreactors

Microorganisms in large-scale bioreactors are exposed to heterogeneous environmental conditions due to physical mixing constraints. Nutritional gradients can lead to transient expression of energetically wasteful stress responses and as a result, can reduce the titres, rates and yields of a bioprocess at larger scales. To what extent these process parameters are impacted is often unknown and therefore bioprocess scale-up comes with major risk. Designing platform strains to account for these intermittent stresses before introducing synthesis pathways is one strategy for de-risking bioprocess development. For example, Escherichia coli strain RM214 is a derivative of wild-type MG1655 that has had several genes and whole operons removed from its genome based on their metabolic cost. In this study, we engineered E. coli strain RM214 (referred to as WG02) to produce octanoic acid from glycerol in batch-flask and fed-batch bioreactor cultivations and compared it to an octanoic acid-producing E. coli MG1655 (WG01). In batch flask cultivations, the two strains performed similarly. However, in carbon limited fed-batch bioreactor cultivations, WG02 provided a greater than 22% boost to biomass compared to WG01 while maintaining similar titres of octanoic acid. Reducing the biomass accumulation of WG02 with nitrogen limited fed-batch cultivation resulted in a 16% improvement in octanoic acid titre over WG01. Finally, in a scale-down system consisting of a stirred tank reactor (representing a well-mixed zone) and plug flow reactor (representing an intermittent carbon starvation zone), WG02 again improved octanoic acid titre by almost 18% while maintaining similar biomass concentrations as WG01.

59 BASIC BIOLOGICAL SCIENCES↗

Bioreactor Optimization through Multi-Phase Flow Models (CRADA Final Report)

Chemical manufacturing uses 29% of energy in the United States and produces 925 million metric tons of CO2 annually. Biomanufacturing offers the potential to leverage America’s rich agricultural resources to produce critical chemicals such as lubricants, pharmaceutical precursors, and components of energetic materials that today are sourced extensively from overseas. The bioreactors used in biomanufacturing applications, such as one developed by Capra Biosciences, involve multiphase flow of biofilm-coated solid support particles that are continuously circulated in a fluidized state within the reactor along with a constant supply of oxygen via an aeration mechanism. In this project, Capra Biosciences and LBNL developed a multiscale modeling framework to simulate the multiphase flows of solid particles in a liquid-gas bubble mixture that occurs in the bioreactor using the current MFIX-Exa software, an opensource multiphase flow solver developed and maintained at LBNL and NETL. By leveraging HPC capabilities, this high-fidelity multiscale model was used to inform design decisions for bioreactor architecture to make them operationally efficient.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Improving bioenergy recovery from municipal wastewater with a novel cloth-filter anaerobic membrane bioreactor

Anaerobic membrane bioreactors (AnMBR) have been used for treating high-strength industrial wastewater at full-scale and the potential to use them for mainstream municipal wastewater treatment presents an important opportunity to turn energy-intensive plants into net-energy producers. However, several limitations of the AnMBR technology have prevented their adoption in the municipal wastewater industry, namely, high membrane cleaning energy demand and low membrane flux. This study demonstrated a novel AnMBR configuration that uses a commercially available cloth filter technology to address the key limitations of cleaning energy and membrane flux. The cloth filter anaerobic membrane bioreactor (CFAnMBR) is comprised of an anaerobic fixed-film bioreactor coupled with a cloth filter membrane with nominal pore size of 5 µm. The pilot CFAnMBR was operated for 150 days through the winter at a municipal wastewater plant in central Illinois (minimum/average influent temperature 5/13°C). The CFAnMBR increased membrane flux by more than 2 orders of magnitude (3,649 ± 1,246 L per meter squared per hour) and reduced cleaning energy demand by 78%—92% (0.0085 kWh/m 3 ) relative to previously reported AnMBR configurations. With the CFAnMBR, average chemical oxygen demand and total suspended solids removal were 66% and 91%, respectively, and were shown to be increased up to 88% and 96% by in-line coagulant dosing with ferric chloride. Average headspace methane yield was 154 mL CH 4 /g COD removed by the end of the study period with influent temperatures of 11°C± 4°C. The CFAnMBR resolves major limitations of AnMBR technology by employing a commercially-available technology already used for other municipal wastewater treatment applications.

59 BASIC BIOLOGICAL SCIENCES↗

Methane Conversion and Byproduct Determination in a Hollow Scaffold Solid State Bioreactor

The concern over greenhouse gases, methane (CH 4 ) and carbon dioxide (CO 2 ), is increasing rapidly. There have been strides to find solutions to this global issue but there is not a clear path to a successful end goal. The concentration of CH 4 and CO 2 in the atmosphere has increased significantly over the last 60 years, methane is a great source of concern due to its ability to trap a high amount of heat in the atmosphere. These greenhouse gases contribute to global warming which has caused changes in the environment, including the melting of ice caps, and altered weather patterns. Solutions for these pressing challenges have led to different avenues of methane mitigation one of which is the development of solid-state bioreactors. These reactors harness the power of biological species that have evolved to use methane as an energy source. These methanotrophs, Methylomicrobium buryatense (5GB1), have been known to produce acetate and formate as a byproduct of the methane consumption cycle. The development of Hollow Scaffold Solid State Bioreactors (HS-SSBR) utilizes these microorganisms by way of hydrogel immobilization and infiltration of 3D printed scaffolds. The scaffolds act as a substrate for methanotroph growth and methane interaction. Methane consumption was monitored by way of gas sensors which indicated a reduction in methane concentration during the first 4 hours of closed loop methane recirculation. The byproducts of formate and acetate were confirmed by way of 1 H-NMR which indicated the 5GB1 methanotrophs were producing these molecules as a result of methane consumption.

36 MATERIALS SCIENCE↗

Genomics Characterization of an Engineered Corynebacterium glutamicum in Bioreactor Cultivation Under Ionic Liquid Stress

Corynebacterium glutamicum is an ideal microbial chassis for production of valuable bioproducts including amino acids and next generation biofuels. Here we resequence engineered isopentenol (IP) producing C. glutamicum BRC-JBEI 1.1.2 strain and assess differential transcriptional profiles using RNA sequencing under industrially relevant conditions including scale transition and compare the presence vs absence of an ionic liquid, cholinium lysinate ([Ch][Lys]). Analysis of the scale transition from shake flask to bioreactor with transcriptomics identified a distinct pattern of metabolic and regulatory responses needed for growth in this industrial format. These differential changes in gene expression corroborate altered accumulation of organic acids and bioproducts, including succinate, acetate, and acetoin that occur when cells are grown in the presence of 50 mM [Ch][Lys] in the stirred-tank reactor. This new genome assembly and differential expression analysis of cells grown in a stirred tank bioreactor clarify the cell response of an C. glutamicum strain engineered to produce IP.

59 BASIC BIOLOGICAL SCIENCES↗

A reacting multiphase computational flow model for 2,3-butanediol synthesis in industrial-scale bioreactors

The microbe, Zymomonas mobilis, can efficiently convert sugars to 2,3 butanediol (BDO), an important intermediate for downstream chemical products, only in a well-controlled microaerated environment. However, controlling oxygen distribution in industrial-scale bioreactors is challenging, and at-scale BDO production is hard to optimize using traditional engineering methods. This study takes a step towards addressing this problem through a computational model for reacting multiphase flows in large-scale bioreactors. A phenomenological metabolic model was first developed and validated against experiments, and then it was coupled to a multiphase computational fluid dynamics (CFD) solver using a subcycling algorithm for simulating long conversion times (~30 hours). Large-scale (~500 m 3 ) bubble column simulations using this coupled approach demonstrated a 25% improvement in BDO yield with low sparging rates (0.002 m/s) and low height-to-diameter ratio (0.875) compared to a baseline bubble column (35 m height, 5 m diameter) with a superficial gas velocity of 0.06 m/s.

09 BIOMASS FUELS↗

Enhancing the Functionality of a Hollow Scaffold Solid State Bioreactor via Computer Aided Design Optimization

The concern over greenhouse gases, methane (CH 4 ) and carbon dioxide (CO 2 ), is increasing rapidly. There have been strides to find solutions to this global issue but there is not a clear path to a successful end goal. The concentration of CH 4 and CO 2 in the atmosphere has increased significantly over the last 60 years, methane is a great source of concern due to its ability to trap a high amount of heat in the atmosphere. These greenhouse gases contribute to global warming which has caused changes in the environment, including the melting of ice caps, and altered weather patterns. Solutions for these pressing challenges have led to different avenues of methane mitigation one of which is the development of solid-state bioreactors. These reactors harness the power of biological species that have evolved to use methane as an energy source. The development and optimization of Hollow Scaffold Solid State Bioreactors (HS-SSBR) has become readily available due to the advancements in additive manufacturing technology and accessibility of computer aided design (CAD) software. With laboratory scale experiments, time and effort are of great importance. Enhancing the design of the HS-SSBR to create a more user-friendly interface, but also increase the functionality of the reactor. The reactor's design improvements focus on better dispersion of methane and circulation of media.

36 MATERIALS SCIENCE↗

Recovery of high-quality calcium phosphate fertilizer products from anaerobic membrane bioreactor treated swine wastewater

The aim of this study is the sustainable recovery of phosphorus as high-quality calcium phosphate from anaerobic membrane bioreactor treated swine permeate for targeted use as fertilizer or raw material for the fertilizer industry. Phosphorus removal efficiencies from treated swine permeate were evaluated by adding various calcium/phosphorus molar ratios ranging from 1/1 to 12/1. Results showed that removal efficiencies were inconsistent in duplicate trials at the same calcium doses (maximum P removal 93% in Trial 1 and <20% removal in Trial 2). The variability in P removal was due to the high bicarbonate alkalinity of the swine permeate, which buffered the system and thereby prevented it from reaching alkaline pH conditions ideal for P removal. Total alkalinity and initial solution pH had the greatest impact on P removal and caused unintended precipitation of non-specific calcium minerals (Calcite). Further, the carbonate alkalinity from the permeate was removed using process modifications that included acid addition and aeration for removal as CO 2 . Carbonate removal resulted in 97% P removal with increased total P content (11.8% P) in the final product and better solubility. Additional COD removal was also observed during the flocculation process.

09 BIOMASS FUELS↗

Using a recirculating anaerobic dynamic membrane bioreactor to treat hydrothermal liquefaction aqueous by-product

Hydrothermal liquefaction (HTL) has the potential to improve resource recovery at water resource recovery facilities (WRRF), but the production of a high-strength aqueous by-product (HTL-aq) is hampering HTL implementation. The formation of biofilms in anaerobic digestion have been shown to be useful when degrading recalcitrant compounds present in HTL-aq due to the promotion of direct interspecies electron transfer (DIET) and increase in the microbial activity of syntrophic and methanogenic populations. The Recirculating Anaerobic Dynamic Membrane Bioreactor (RAnDMBr) was able to degrade 65% of the chemical oxygen demand (COD) at 1.5 ± 0.2 g COD LR −1 day −1 and 5.6 ± 2.3 days producing 0.19 ± 0.02 LCH4 gCOD fed −1 . However, adding a solution rich in nutrients on a daily basis was necessary. The system presented microbial populations able to degrade aromatic compounds (i.e., Anaerolinaceae) to perform DIET and syntrophy (i.e., Syntrophus) and methanogens (i.e., Methanobacterium and Methanosarcina) with the biofilm having a higher relative abundance of methanogens than the suspended biomass. Increasing the organic loading rate to 2 g COD LR −1 day −1 caused inhibition in the system by accumulation of volatile fatty acids, probably due to an increase in phenol, N-heterocyclic and aromatic compounds. Overall, this research shows that the RAnDMBr can be used to treat HTL-aq in WRRF without inhibition at OLRs of 1.5 ± 0.2 g COD LR −1 day −1 or lower, making HTL-aq treatment more feasible. Future research should focus co-digestion of HTL-aq with a co-substrate rich in nutrients and on fouling mitigation strategies that will allow to increase the recirculation ratio to promote advective substrate transport through the biofilm.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Halophyte biorefinery for polyhydroxyalkanoates production from Ulva sp. Hydrolysate with Haloferax mediterranei in pneumatically agitated bioreactors and ultrasound harvesting

Here, the present study tested the outdoor cultivation of Haloferax mediterranei for PHA production from green macroalgae Ulva sp. in pneumatically agitated bioreactors and applied ultrasonic separation for enhanced settling of archaeal cells. Scaled-up cultivation (40 L) yielded maximum biomass productivity of 50.1 ± 0.11 mg·L -1 ·h -1 with a PHA productivity of 27 ± 0.01 mg·L -1 ·h -1 and conversion yield of 0.107 g PHA per gram UlvaDW. The maximum mass fraction of PHA achieved in biomass was calculated to be 56% w/w. Ultrasonic harvesting of Hfx. mediterranei cells approached 30% removal at energy inputs around 7.8 kWh·m -3 , and indicated no significant aggregation enhancement by Ca 2+ addition. Molecular weight analysis showed an increase in Polydispersity Index (PDI) when the corresponding air velocities were increased suggesting that the polymer was more homogeneous at lower mixing velocities. The current study demonstrated scalable processes for PHA production using Ulva sp. feedstock providing new technologies for halophilic biorefinery.

09 BIOMASS FUELS↗

Optimization based process modeling of an anaerobic membrane bioreactor system: Application to swine wastewater

To maintain current levels of consumption in the economy with the dwindling supply of non-renewable material and energy, alternative resource streams more traditionally viewed as waste streams must be considered. Fermentation of high-strength wastewaters is one such pathway that allows for the recovery of energy, nitrogen, phosphorus, and carbon compounds. Anaerobic membrane bioreactors (AnMBRs) are an emerging technology that allow for the digestion of wastewater in a much smaller footprint than traditional anaerobic digesters. Adoption of this technology into industry has been limited by membrane capital and cleaning costs, but these costs may be offset through the recovery of valuable products. To evaluate the viability of AnMBR technology in the context of swine wastewater treatment, an optimization-based process model built upon Anaerobic Digestion Model No. 1 (ADM1) has been developed. Modeling results show that a swine wastewater stream provides potential for net positive energy generation from the AnMBR system in most cases. Sensitivity analyses around important variables were conducted to determine focus areas for future research into AnMBR technology and evaluate the robustness of the model to microbial variables that may change with different microbial communities.

09 BIOMASS FUELS↗

Predicting Anaerobic Membrane Bioreactor Performance Using Flow-Cytometry-Derived High and Low Nucleic Acid Content Cells

Having a tool to monitor the microbial abundances rapidly and to utilize the data to predict the reactor performance would facilitate the operation of an anaerobic membrane bioreactor (AnMBR). This study aims to achieve the aforementioned scenario by developing a linear regression model that incorporates a time-lagging mode. The model uses low nucleic acid (LNA) cell numbers and the ratio of high nucleic acid (HNA) to LNA cells as an input data set. First, the model was trained using data sets obtained from a 35 L pilot-scale AnMBR. The model was able to predict the chemical oxygen demand (COD) removal efficiency and methane production 3.5 days in advance. Subsequent validation of the model using flow cytometry (FCM)-derived data (at time t – 3.5 days) obtained from another biologically independent reactor did not exhibit any substantial difference between predicted and actual measurements of reactor performance at time t. Further cell sorting, 16S rRNA gene sequencing, and correlation analysis partly attributed this accurate prediction to HNA genera (e.g., Anaerovibrio and unclassified Bacteroidales) and LNA genera (e.g., Achromobacter, Ochrobactrum, and unclassified Anaerolineae). In summary, our findings suggest that HNA and LNA cell routine enumeration, along with the trained model, can derive a fast approach to predict the AnMBR performance.

42 ENGINEERING↗

Biogeochemical Controls on Wood Degradation as a Source of Bioavailable Carbon in Denitrifying Bioreactors

Woodchip bioreactors (WBRs) are important tools for the removal of nitrate in agricultural drainage, but their effectiveness is often limited by the slow degradation of lignocellulosic wood residues into bioavailable forms of carbon that fuel denitrifying microorganisms. Here, we examine biogeochemical factors regulating wood degradation in saturated woodchip beds, with a focus on the effects of dissolved oxygen (DO), iron (Fe), and manganese (Mn) in generating oxidative activity that can enhance wood decomposition. Woodchips from a 10-year-old WBR were characterized with bulk techniques and a novel combination of μX-ray scattering, μXRF, and μXANES to visualize the depletion of crystalline cellulose as a proxy for wood degradation. Woodchips from upstream portions of the reactor exhibited the greatest degradation, probably due to greater DO exposure, and degradation was localized to a 100 to 200 μm thick surface layer that was also associated with higher concentrations of Fe and Mn. Greater degradation was associated with faster nitrate removal. μXANES analysis of Fe and Mn in the surface layer indicated the presence of a microenvironment in which oxygenation reactions of Fe(II) and Mn(II) could contribute to the formation of reactive oxidants involved in the degradation of lignocellulose. In conclusion, our results provide new insight into biogeochemical properties that influence wood decomposition in WBRs at both micro- and macroscales and how these wood degradation processes are coupled with denitrification.

36 MATERIALS SCIENCE↗