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Development of a Biofilm Bioreactor for Enhanced Ethanol Production Mahipal Reddy Kunduru Iowa State University

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Development of a Biofilm Bioreactor for Enhanced Ethanol Production Mahipal Reddy Kunduru Iowa State University Iowa State University Capstones, Theses and Retrospective Theses and Dissertations Dissertations 1994 Development of a biofilm bioreactor for enhanced ethanol production Mahipal Reddy Kunduru Iowa State University Follow this and additional works at: https://lib.dr.iastate.edu/rtd Part of the Agriculture Commons, Food Microbiology Commons, and the Microbiology Commons Recommended Citation Kunduru, Mahipal Reddy, "Development of a biofilm bioreactor for enhanced ethanol production " (1994). Retrospective Theses and Dissertations. 11280. https://lib.dr.iastate.edu/rtd/11280 This Dissertation is brought to you for free and open access by the Iowa State University Capstones, Theses and Dissertations at Iowa State University Digital Repository. It has been accepted for inclusion in Retrospective Theses and Dissertations by an authorized administrator of Iowa State University Digital Repository. For more information, please contact [email protected]. INFORMATION TO USERS This manuscript has been reproduced from the microfilm master. UMI films the text directly from the original or copy submitted. Thus, some thesis and dissertation copies are in Q^ewriter face, while others may be from aity type of computer printer. Hie quality of this Teprodaction is dependent upon the quali^ of the copy submitted. Broken or indistinct print, colored or poor quality illustrations and photographs, print bleedthrough, substandard margins, and inq)roper alignment can adversely affect reproduction. In the unlikely event that the author did not send UMI a complete manuscript and there are missing pages, these will be noted. Also, if unauthorized copyright material had to be removed, a note will indicate the deletion. Oversize materials (e.g., maps, drawings, charts) are reproduced by sectioning the original, beginning at the upper left-hand comer and continuing from left to right in equal sections with small overlaps. Each original is also photographed in one exposure and is included in reduced form at the back of the book. Photographs included in the original manuscript have been reproduced xerographically in this copy. Higher quality 6" x 9" black and white photographic prints are available for ai^ photographs or illustrations appearing in this copy for an additional charge. Contact UMI directiy to order. A Bell & Howell Information Company 300 North Zeeb Road. Ann Arbor. Ml 48106-1346 USA 313/761-4700 800/521-0600 Order Number 9518403 Development of a biofilm bioreactor for enhanced ethanol production Kunduru, Mahipal Reddy, Ph.D. Iowa State University, 1994 UMI 300N.ZeebRd. Ann Arbor, MI 48106 Development of a biofilm bioreactor for enhanced ethanol production by Mahipal Reddy Kunduru A Dissertation Submitted to the Graduate Faculty in Partial Fulfillment of the Requirements for the Degree of DOCTOR OF PHILOSOPHY Department: Food Science and Human Nutrition Major: Food Science and Technology Approved: Signature was redacted for privacy. Signature was redacted for privacy. For thif Major Department Signature was redacted for privacy. For the Graduate College Iowa State University Ames, Iowa 1994 ii To my parents: Lakshma Reddy and Sulochana, my brother late Venugopal, and my wife and son: Sudha and Anish iii TABLE OF CONTENTS Page LIST OF FIGURES vii LIST OF TABLES x ABSTRACT xi GENERAL INTRODUCTION 1 Dissertation organization 2 LITERATURE REVIEW 3 History 3 Applications 4 Costs of ethanol production 6 Microbial pathways for ethanol production 8 High rate bacterial fermentations 13 Feed stocks used for ethanol production 13 Production of ethanol from whey 14 Production of ethanol from Jerusalem artichokes IS Production of ethanol from sweet sorghum 15 Production of ethanol from cellulose and cellobiose 16 Immobilized cell systems 17 Definition of immobilized cell systems 17 Criteria for selecting immobilized cell system 18 Advantages of immobilized cell systems 18 Ethanol production using immobilized cell systems 20 Ethanol production by mechanically-contained cell systems 20 Ethanol production using attached cell systems 21 Adsorption of cells to solid supports 22 Attachment by covalent bonding and cross-linking 24 iv Ethanol production using entrapped cell systems 25 Alginate entrapped cell systems 26 K-Carrageenan entrapped cell systems 28 Entrapment of cells within other polymeric matrices 28 Limitations of entrapped cell systems 29 Ethanol production using flocculated cell systems 30 Types of bioreactors used for ethanol fermentation 31 Batch fermentation 31 Batch fermentor 32 Continuous fermentation 32 Two-stage continuous flow bioreactor 35 Multi-stage continuous stirred tank reactor 36 Continuous fermentation with recycle 38 Continuously stirred tank reactors with recycle 38 Membrane fermentor 39 Tower fermentor 40 Immobilized column reactor without support 41 Continuous fermentation with cell recovery 41 Hollow fiber reactor 41 Continuous dynamic immobilized bioreactor 41 Fluidized bed fermentor 43 Multistage fluidized bed bioreactor 44 Solid substrate fermentation 46 Solid-phase fermentation 46 Extractive fermentation 46 Membrane extractive fermentation 48 Vacuum fermentation 49 Integrated fermentation unit 51 Immobilized yeast reactor coupled with membrane pervaporation unit 51 Biofilm bioreactors for ethanol production 51 Packed bed fermentor 53 Plug flow bioreactor 53 Packed-column bioreactor 55 Rotating biological surface bioreactor 55 Rotating fiber disc fermentor 56 Rotary drum fermentor 58 V EVALUATION OF PLASTIC-COMPOSITE SUPPORTS FOR ENHANCED ETHANOL PRODUCTION IN BIOFILM REACTORS 59 Abstract 59 Introduction 61 Materials and Methods 63 Microorganisms and media 63 Support materials 64 Evaluation of biofilm 65 Continuous ethanol fermentation 65 Analysis of culture broth 66 Results and Discussion 67 Percent yield 67 Productivity 68 Ethanol production 69 Support materials 70 Acknowledgements 72 References 72 CONTINUOUS ETHANOL PRODUCTION IN BIOFILM REACTORS USING ZYMOMONAS MOBIUS SACCHAROMYCES CEREVISIAE 83 Abstract 83 Introduction 85 Materials and Methods 87 Microorganisms and media 87 Support materials 87 Bioreactors 88 Continuous fermentation 90 Evaluation of biofilm 90 Analysis of culture broth 90 Residence time 91 vi Results and Discussion 91 Percent yield 91 Ethanol productivity 92 Ethanol production 92 Support materials and bioreactor design 95 Conclusions 96 Acknowledgements 97 Rererences 97 SUMMARY AND CONCLUSIONS 106 BIBLIOGRAPHY 109 ACKNOWLEDGEMENTS 118 vii LIST OF FIGURES Page REVIEW OF LITERATURE Figure 1. Formation of ethanol from glucose by the Embden-Meyerhoff- Pamas pathway 10 Figure 2. Formation of ethanol from glucose by the Entner-Duodoroff pathway 11 Figure 3. Formation of ethanol from glucose and xylose by the heterolactic fermentation pathway 12 Figure 4. Schematic diagram of a batch type fermentor 33 Figure 5. Schematic diagram of two-stage immobilized bioreactor for continuous ethanol production 37 Figure 6. Schematic diagram of a multistage CSTR 38 Figure 7. Schematic diagram of a membrane recycle fermentor 39 Figure 8. Schematic diagram of a tower fermentor 40 Figure 9. Schematic diagram of a continuous dynamic immobilized biocatalyst bioreactor 42 Figure 10. Schematic diagram of a fluidized bed fermentor 43 Figure 11. Schematic diagram of a multistage fluidized bed fermentor 45 Figure 12. Schematic diagram of a plant for continuous solid-phase fermentation 47 Figure 13. Schematic diagram of a vacuum fermentor 48 Figure 14. Schematic diagram for ethanol production using extractive fermentation 49 Figure 15. Schematic diagram of an extractive fermentor 50 vm Figure 16. Schematic diagram of an immobilized yeast reactor coupled with pervaporation unit 52 Figure 17. Schematic diagram of a vertical packed bed fermentor 54 Figure 18. Schematic diagram of a rotating biological surface bioreactor 56 Figure 19. Schematic diagram of a rotating disc fermentor 57 EVALUATION OF PLASTIC-COMPOSITE SUPPORTS FOR ENHANCED ETHANOL PRODUCTION IN BIOFILM REACTORS Figure 1. Schematic diagram of a biofilm bioreactor 78 Figure 2. Ethanol concentrations, percent yield and ethanol productivities continuous fermentation with Zymomonas mobilis in pure-culture and 10% glucose in the feed 79 Figure 3. Ethanol concentrations, percent yield and productivity in mixed- culture fermentation with Zymomonas mobilis and Streptomyces viridosporus vwth 12.5% glucose in the feed. 80 Figure 4. Ethanol concentrations, yield and productivity in pure culture fermentation with Saccharomyces cerevisiae with 7.5% glucose in the feed 81 Figure 5. Ethanol concentrations, yield and productivity in mixed-culture fermentation with Saccharomyces cerevisiae and Streptomyces viridosporus T7A with 10% glucose in the feed. 82 CONTINUOUS ETHANOL FERMENTATION IN BIOFILM REACTORS USING ZYMOMONAS MOBILIS AND SACCHAROMYCES CEREVISIAE Figure 1. Schematic diagram of a down flow biofilm bioreactor used for continuous fermentation by Zymomonas mobilis 101 Figure 2. Schematic diagram of an upflow biofilm bioreactor used for continuous fermentataion with Saccharomyces cervisiae 102 ix Figure 3. Ethanol concnetration, productivity and yield in a down flow biofilm bioreactor used for continuous fermentation with Zymomonas mobilis (each bar represents the average of two replicate data points taken every day. The fermentors were operated at each dilution rate for 5-7 days. 103 Figure 4. Ethanol concentration, yield and productivity in an upflow biofilm bioreactor used for continuous fermentation with Saccharomyces cerevisae (each bar represents the average of two replicate
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