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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↗

Methane Remediation using Biocatalysts in Gas-Solid Reactor – Challenges and Prospects

One of the engineering grand challenges of the 21 st century is to develop carbon sequestration methods due to human activities. Carbon dioxide and methane are the two most abundant greenhouse gases with methane having a higher global warming potential (GWP) than carbon dioxide. Methanotrophs are a time of bacteria that consumes methane and can produce different kinds of organic acids. Wild methanotrophs produce a range of products and can be specifically selected and genetically engineered to produce a specific product. Improvement of bioreactor design for a solid-gas mass transfer is necessary for this technology to move forward. Poor solubility of methane requires high energy input for the conversion of methane. This paper reviews some relevant technology in bioreactor design of gas and liquid/solid interfaces and describes the scope of the project here at LLNL and the objectives it seeks to achieve in the geometric design of reactor of methanotroph.

36 MATERIALS SCIENCE↗

Computational Fluid Dynamics of Bioreactors with Micro-Aeration

Recent work has probed the potential for using Zymomonas mobilis as a flexible platform for the production of advanced fuels and intermediates. One set of recombinant organisms requires a micro-aerobic environment to promote the production of the desired product (2,3-BDO), but the economics and process-control implications of this approach are uncertain at industrial scale. Computational multi-physics models have the potential to describe the fermentation in detail at multiple scales, reducing the risk of scale-up. A two-phase Euler-Euler CFD model is used alongside a simple model of oxygen uptake to describe this bioreaction. A few reactor vessels, including airlift and CSTR bioreactors, are analyzed at multiple scales, regions of oxygen-depletion and over-oxygenation are characterized, and the bioreactors are compared. We show that it is difficult to achieve homogenous oxygen concentrations in industrial-scale CSTR reactors and that advanced bioreactor designs are needed for economical operation.

09 BIOMASS FUELS↗

CFD Simulation of Aerobic Gas Fermentation to Enable Commercial Conversion of CO 2 into Aquaculture and Animal Feed: Cooperative Research and Development (Final Report)

NovoNutrients’ fermentation technology uses energy from hydrogen to transform industrial CO2 emissions into premium animal feed ingredients and other valuable products. A single NovoNutrients’ commercial manufacturing plant will capture and convert over 200,000 tons/yr of CO2 into over 100,000 tons/yr of high-protein feed. Key to the rapid and widespread deployment of the technology is maximization of its productivity and energy efficiency. Robust, physically based computational models of the technology will significantly increase productivity and efficiency, accelerating NovoNutrients’ technology to manufacturing scale. NREL has unique capabilities for creating and running such computational models. NREL's existing aerobic bioreaction computational fluid dynamics (CFD) models will be adapted to NovoNutrients’ gas fermentation (CO2, H2, O2) technology. The multiphysics CFD simulations require thousands of high-performance computing (HPC) node hours to simulate the complex geometries and contents of NovoNutrients’ industrial bioreactors. The experimentally validated CFD models were used to identify optimally efficient and productive bioreactor designs and operating conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Coupling gas purging with inorganic carbon supply to enhance biohydrogen production with Clostridium thermocellum

Clostridium thermocellum is a desirable biocatalyst for biohydrogen production, with a native ability to simultaneously saccharify cellulose and to metabolize released cellodextrins for hydrogen production. During fermentation with C. thermocellum , partial pressures of two gases - CO 2 and H 2 - are critical drivers of overall reaction kinetics. Biohydrogen production is enhanced by maintaining a low hydrogen partial pressure, while high concentrations of dissolved CO 2 promote microbial biomass synthesis. Our study evaluates the inherent trade-offs between hydrogen stripping and inorganic carbon supply for optimized biohydrogen synthesis. Here, we find that nitrogen sparging at low flow rates increases hydrogen production when compared with an equivalent nitrogen overlay, but that high rates of nitrogen sparging inhibit cell growth and hydrogen production. Decreasing dissolved hydrogen partial pressure via nitrogen sparging also lowers the production of reduced metabolites, including lactate and ethanol. To address potential stripping of inorganic carbon from the production medium, we supplemented CO 2 to the sparging gas and co-optimized for gas flow rate and for the CO 2 fraction of the sparging gas. Total hydrogen production increased from 50 mmol∙L -1 in the base condition, when the bioreactor was sparged with 0.1 LPM of pure nitrogen, to 181.3 mmol∙L -1 when sparged with 1.3 LPM of 33 % CO 2 , demonstrating that biohydrogen production is highly sensitive to both parameters. Fine sensitivity of biohydrogen production to sparging conditions highlights the critical importance of bioreactor design and operation to achieve maximum H 2 removal without compromising inorganic carbon supply to bacterial central metabolism.

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↗

Production of Renewable Natural Gas from Waste Carbon Dioxide Sources (CRADA Final Report)

This CRADA provides new funding from SoCalGas and DOE's BETO and FCTO Offices focused hydrogen mass transfer limitations in H2@Scale processes. The project leverages the existing hydrogen production capabilities at the Energy Systems Integration Facility (ESIF) and SoCalGas' 700 L bioreactor system designed, built, and delivered to NLR under the first phase of this CRADA. This Joint Work Statement will cover new hardware modifications between NLR's electorlyzer stack and the SoCalGas bioreactor located outdoors. The new hardware and controls will provide researchers with the tools needed to obtain preliminary experimental data for a non-provisional application due in July 2019. The IP being developed is expected to improve the productivity of the bioreactor and would have wider impacts on other end-use processes using pressurized hydrogen (H2). In addition, this new funding enhances an existing BETO Biopower award by developing a 10-15 kW electrolyzer that is scalable to the MW-class with reduced capital cost and higher efficiency aimed at improving H2 mass transfer to downstream processes, like biomethanation. Finally due to the close-coupling between the electrolyzer stack and bioreactor, R&D will focus on cell retention, nutrient maintenance, optimal water management and process controls.

08 HYDROGEN↗

Multiphysics Computational Fluid Dynamics for Design and Scale-Up of CO 2 /Syngas Bioreactors [Poster]

What are we trying to do? Develop validated, high fidelity computational models for gas fermentation using CO 2 , CO and H 2 . How is it done today? Microbiological advances are made at the lab scale in well mixed reactors. Process scale-up remains an open question when considering novel microorganisms/reaction systems. Why is this important? Lab-to-production scale transition is required to achieve CO 2 conversion at Mton/Gton scale and computational models can de-risk/accelerate this transition.

09 BIOMASS FUELS↗

Multiphysics Computational-Fluid-Dynamics (CFD) for Design and Scale-Up of Gas Bioreactors that Utilize CO2

Gas fermentation technology offers sustainable and high carbon-efficiency routes to fuels and chemicals. However, efficiently delivering low-solubility substrate gases to production-scale bioreactors is a significant technical challenge that could limit productivity. We perform fundamental and applied multiphysics computational fluid dynamics (CFD) research targeting specific challenges of gas delivery in fermentation systems that utilize varied gas-compositions, for e.g. CO2/CO/CH4/H2 substrates: bubble dynamics, coupled mass-transfer and reaction, that can lead to optimal reactor designs at scale. This work will support BETO goals towards greenhouse gas reduction, derisking technologies toward commercialization/deployment and sustainable-aviation-fuel synthesis targets.

BIOMASS FUELS↗

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↗

Integration of pH Control into Chi.Bio Reactors and Demonstration with Small-Scale Enzymatic Poly(ethylene terephthalate) Hydrolysis

Small-scale bioreactors that are affordable and accessible would be of major benefit to the research community. In previous work, an open-source, automated bioreactor system was designed to operate up to the 30 mL scale with online optical monitoring, stirring, and temperature control, and this system, dubbed Chi.Bio, is now commercially available at a cost that is typically 1–2 orders of magnitude less than commercial bioreactors. In this work, we further expand the capabilities of the Chi.Bio system by enabling continuous pH monitoring and control through hardware and software modifications. For hardware modifications, we sourced low-cost, commercial pH circuits and made straightforward modifications to the Chi.Bio head plate to enable continuous pH monitoring. For software integration, we introduced closed-loop feedback control of the pH measured inside the Chi.Bio reactors and integrated a pH-control module into the existing Chi.Bio user interface. We demonstrated the utility of pH control through the small-scale depolymerization of the synthetic polyester, poly(ethylene terephthalate) (PET), using a benchmark cutinase enzyme, and compared this to 250 mL bioreactor hydrolysis reactions. The results in terms of PET conversion and rate, measured both by base addition and product release profiles, are statistically equivalent, with the Chi.Bio system allowing for a 20-fold reduction of purified enzyme required relative to the 250 mL bioreactor setup. Through inexpensive modifications, the ability to conduct pH control in Chi.Bio reactors widens the potential slate of biochemical reactions and biological cultivations for study in this system, and may also be adapted for use in other bioreactor platforms.

09 BIOMASS FUELS↗

Indoor Air Quality (IAQ) Monitoring for Space Farming Institute [Slides]

Through the U.S. Department of Energy's Energy to Communities (E2C) program, NREL, other national laboratory experts, and select organizations provide Expert Match - free, short-term technical assistance to address near-term energy challenges and questions. Expert Match is for community stakeholders who have decision-making power or influence in their community but need access to additional energy expertise to inform key upcoming decisions. This Expert Match request supported the Space Farming Institute, a nonprofit organization located in Anchorage, AK, with an indoor air quality analysis. The NREL team analyzed indoor air quality data provided by the Space Farming Institute, which experts at PNNL used to design an indoor bioreactor to grow Ulva algae for indoor air quality mitigation purposes.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Biomethanation to Upgrade Biogas to Pipeline Grade Methane

NREL is working closely with DOE, Electrochaea GmbH, and Southern California Gas Company (SoCalGas) to reduce costs of a biomethanation process capable of megawatt-scale deployment that upgrades organic biogas waste streams to produce pipeline quality renewable natural gas (RNG). Biomethanation is a two-step process using a single-celled methanogenic archaea that converts low-carbon low-cost hydrogen (H2) and waste carbon dioxide (CO2) to produce renewable methane (CH4). The process upgrades the biogenic CO2 - while allowing the CH4 to pass through - from biogas sources like dairies, wastewater treatment plants, and landfills. The CH4 produced is a drop-in direct replacement fuel and producers can participate in the growing number of carbon markets; like California's Low Carbon Fuel Standard and the Federal Renewable Fuel Standard. NREL and Argonne National Laboratory have completed a life cycle analysis using the GREET model to show that the biomethanation process produces RNG that is carbon negative even when H2 production via low-temperature water electrolysis is driven by the existing carbon intensity of California's electricity grid. And of course, even further carbon negative (-233 kg CO2e/kWh) when the electricity is produced from low-carbon sources like wind and solar. Leveraging lessons learned from operating SoCalGas' 700L 18-bar bioreactor system, NREL is designing and building a flexible RD&D platform that will enable field trials at biogas and other CO2 sources. A custom 16' long trailer will house a 20L 18-bar bioreactor, 3 - 25 kW proton exchange membrane electrolyzer, and dosing, thermal, and controls systems to support operations with only power, biogas, and water feedstocks required by the field locations. The end-of-project goal is to demonstrate pipeline quality RNG production (> 95% CH4, < 4% H2, <1% CO2, < 0.2% O2 and < 4 parts per million H2 sulfide) using real biogas feedstocks - thereby recycling both greenhouse gases for injection into the natural gas network or to be used onsite.

biogas upgrading↗

BETO 2021 Peer Review - Biological Upgrading of Sugars (BUS) 2.3.2.105

The Biological Upgrading of Sugars (BUS) project directly targets the anaerobic conversion of lignocellulosic feedstocks into intermediate molecules readily upgradeable to fuel precursors. Recent efforts on the BUS project have a particular emphasis on the biological production of butyric acid, an intermediate that can be readily upgraded to sustainable aviation fuel, diesel blend-stocks, and high value chemicals. The BUS project approaches this direction through a combination of strain engineering, fermentation process engineering, development of novel separations technologies, and the design and build of pilot scale systems. Our ultimate project goal is to develop an integrated cost-effective process at pilot scale to achieve DOE's MYPP targets of $2.50/GGE. The major thrust of the BUS project over the last project cycle was on the development of integrated processes surrounding the anaerobic production of carboxylic acids using diverse Clostridium species. We developed and expanded genetic tools for several Clostridium species and rewired microbial metabolism in an attempt to maximize substrate utilization and flux towards butyric acid. We designed and built novel bioreactors with an in situ product recovery system enabling the biological production and recovery of highly purified acids. We leveraged this system to generate 100s of grams of acid from corn stover hydrolysate. In this presentation we highlight data surrounding our proposed process and accompanying results from technoeconomic and life-cycle analyses of our integrated process. Finally, we detail plans of our pilot scale reactor system that is in process and discuss our future routes towards achieving economically viable and sustainable diesel and jet blendstocks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Evaluate Synergies of Using Hydrothermal Liquefaction and Anerobic Digestion Treatment Technologies for Wastewater Resource Recovery Facilities (CRADA 516 Final Report)

The research focuses on utilizing a new anaerobic digestion (AD) configuration to treat the aqueous by-product generated by hydrothermal liquefaction (HTL) of sewage sludge. This report found that for Anaerobic Digestion for HTL By-product, Anaerobic biofilms can degrade some HTL wastewater contaminants, but co-digestion is essential to address nutrient deficiencies and optimize performance. Without AD, toxicity of HTL aqueous streams may limit broader adoption in wastewater treatment plants (WWTPs). Great Lakes Water Authority (GLWA) used an innovative reactor design, involving a dynamic membrane anaerobic bioreactor to promote biofilm growth, improving contaminant degradation. The tree-like structure inside the reactor supports biofilm development with recirculation enhancing microbial activity. Overall, a 70% chemical oxygen demand (COD) removal was achieved, although nutrient supplementation is required for stability. The reactor achieved a diverse microbial community, including methanogens and bacteria capable of degrading phenols and aromatics.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Three-Dimensional Bubble Fluidics in Architected Porous Media

Gas bubble flows in porous media often exhibit complex and seemingly unpredictable behaviors that are difficult to control. This lack of control limits the ability to design effective devices which manage multiphase flows. Here, we show how the design of 3D printed pores can deterministically control the flow path of an injected gas stream. Open cell structures can be designed to shape the gas/liquid interface with fidelity to control how the two phases are distributed throughout a porous material. The distributed gas volume is free to interact physically and chemically with the surrounding liquid phase, an effect we exploit to create a logical control gate to redirect flows within a lattice. This also allows us to design architectures for reactive capture and aerating bioreactors, resulting in patterned boundaries which can make more effective use of the liquid and gas reagents.

3D microfluidics↗

Application of Machine Learning to Improve Biobased Glucaric Acid Production

Kalion, Inc. is an industrial biotechnology manufacturer of high-purity chemicals from biomass including glucaric acid to be used in the industrial, material, and pharmaceutical markets. The project goal is application of machine learning in conjunction with high-throughput cultivations and metabolomics to understand and overcome two different challenges: (i) improve glucaric acid productivity (the rate of production slows considerably after 48 hours, which limits the overall productivity that can be achieved in the process), and (ii) decrease its production costs (components from complex media are necessary to achieve robust production). Through a series of experiments, a set of metabolites contained in rich media that improved performance were identified using metabolomics, high throughput cultivations in bioreactors, and machine learning-friendly experimental designs. It was found that the substrate feeding strategy was the potential major driver to enhance bacterial performance of glucaric acid production. The major industrial impacts by this project are the improvement of the production process technology, as well as advancing infrastructures and workflows (where machine learning approaches in conjunction with high-throughput cultivation and metabolomics are used) to improve the analyses by making them more rapid and comprehensive.

BIOMASS FUELS↗

Computational Analysis of Different Sparging Systems and their Influence in the Fluid-Dynamic Behavior of Bubble Column Reactors

Bubble column bioreactors are being actively considered for gas fermentation applications, specifically for CO2 utilization, and sugars to fuels conversion. Their main advantages include good mass transfer without any moving parts and low-cost of operation and maintenance. However, the design and scale-up of such reactors is challenging specifically for carbon capture applications where a mixture of gases (e.g. CO2/CO/H2) with variable solubilities is used. The overall performance of scaled-up bioreactors (e.g., mass transfer rate) is largely affected by gas holdup, bubble size distribution (BSD), and multiphase hydrodynamics. We investigate the effect of gas sparger designs on the performance of these large-scale bioreactors using computational fluid dynamics simulations in this work, so as to improve CO2 conversion at scale. The gas distribution systems in bubble column reactors not only determines operational regime, but also affects the evolution of the BSD, which in turn influences interfacial mass transfer and ultimately the efficiency of the gas-liquid exchange process. In addition to the BSD, uniformity in gas sparging affects gas holdup and bubble residence time which constitute important metrics of performance in gas-liquid systems. In this work, we use computational models to simulate high fidelity representations of different sparger designs and their effect on the operation of a bubble column reactor. Four different types of spargers have been selected for the computational study (Fig. 1): ladder, multi-ring, single-ring and toroidal. Their effect on superficial velocity, gas holdup mixing efficiency, and BSD will be evaluated in this work. The model uses a multiphase Eulerian framework similar to [1] and include a composition of mixtures of H2/CO/CO2 gases, common in fermentation applications.

BIOMASS FUELS,MATHEMATICS AND COMPUTING↗