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Notes: Abstract The productivity of a fermentation is proportional to the biomass concentration. The productivity can therefore be increased by retention of the cells in the fermentor. In this study microfiltration was used for cell retention in a fermentation of glucose to ethanol by baker's yeast. Compared to a system without cell retention the productivity could be increased 12-fold to 55 kg/m3 h at a biomass concentration of 135 kg/m3. Maximal ethanol concentrations of 76 kg/m3 were obtained at conditions of growth. At zero growth conditions in the integrated system the ethanol concentration could be increased to about 115 kg/m3, and could be produced for at least 10 hours. The fermentation results in the integrated system could be described reasonably well with a mathematical model based on a different linear inhibition kinetics for growth and substrate consumption.

Notes: Abstract Extraction can successfully be used for in-situ alcohol recovery in butanol fermentations to increase the substrate conversion. An advantage of extraction over other recovery methods may be the high capacity of the solvent and the high selectivity of the alcohol/water separation. Extraction, however, is a comprehensive operation, and the design of an extraction apparatus can be complex. The aim of this study is to assess the practical applicability of liquid-liquid extraction and membrane solvent extraction in butanol fermentations. In this view various aspects of extraction processes were investigated. Thirty-six chemicals were tested for the distribution coefficient for butanol, the selectivity of alcohol/water separation and the toxicity towards Clostridia. Convenient extractants were found in the group of esters with high molar mass. Liquid-liquid extraction was carried out in a stirred fermenter and a spray column. The formation of emulsions and the fouling of the solvent in a fermentation broth causes problems with the operation of this type of equipment. With membrane solvent extraction, in which the solvent is separated from the broth by a membrane, a dispersion-free extraction is possible, leading to an easy operation of the equipment. In this case the mass transfer in the membrane becomes important. With membrane solvent extraction the development of a process is emphasized in which the extraction characteristics of the solvent are combined with the property of silicone rubber membranes to separate butanol from water. In the case of apolar solvents with a high molar mass, the characteristics of the membrane process are determined completely by the solvent. In the case of polar solvents (e.g. ethylene glycol), the permselectivity of the membrane can profitably be used. This concept leads to a novel type of extraction process in which alcohol is extracted with a water-soluble solvent via a hydrophobic semipermeable membrane. This extraction process has been investigated for the recovery of butanol and ethanol from water. A major drawback in all processes with membrane solvent extraction was the permeation of part of the solvent to the aqueous phase. The extraction processes were coupled to batch, fed batch and continuous butanol fermentations to affirm the applicability of the recovery techniques in the actual process. In the batch and fed batch fermentations a three-fold increase in the substrate consumption could be achieved, in the continuous fermentation about 30% increase.

Notes: Abstract In ethanol fermentations inhibition of the microorganism by ethanol limits the amount of substrate in the feed that can be converted. In a process high feed concentrations are desirable to minimize the flows. Such high feed concentrations can be realized in integrated processes in which ethanol is recovered from the fermentation broth as it is formed. In this study ethanol recovery by pervaporation was coupled to glucose fermentations by baker's yeast. Pervaporation was carried out with commercial silicone based hollow-fibre membrane modules with relatively high fluxes. Three different types of process configurations with pervaporation were investigated. Two of these configurations also included cell retention by microfiltration, in order to optimize the productivity. In the systems with pervaporation a feed containing 360 kg/m3 glucose could be converted almost completely. This feed concentration is a factor three higher than in a process without ethanol recovery. The productivity was 14 kg/m3 h in a system with pervaporation only, and could be increased to 43 kg/m3 h in the system with all recycle by microfiltration. The kinetic data suggest that accumulation of inhibitory compounds occurs in the integrated system. The integrated process was relatively easy in operation.

Notes: Abstract Four systems comprising of an ethanol fermentation integrated with microfiltration and/or pervaporation, and a conventional continuous culture, were compared with respect to the performance of the fermentation and economics. The processes are compared on the basis of the same kinetic model. It is found that cell retention by microfiltration leads to lower production costs, compared to a conventional continuous culture. Pervaporation becomes profitable at a high selectivity of ethanol/water separation and low membrane prices.

Notes: Abstract Membrane recycle fermentors are used successfully on laboratory scale to increase the efficiency of fermentation processes. The design of a process on larger scale however is obstructed by the lack of relevant data in literature. Compared to a stand-alone fermentor a membrane recycle fermentor presents new features which must be considered in the design. These features include the use of high density cultures, the additional volume in the membrane section and the circulation of the broth. In this theoretical study these aspects are analyzed with the characteristic time concept, in case of an ethanol fermentation integrated with microfiltration. The analysis shows that depending on the reactor configuration used concentration gradients can be expected. These gradients may decrease the efficiency of the fermentation, or can be advantageous, for example by letting the substrate conversion approach completion in the membrane section.

Notes: Summary In the butanol/isopropanol batch fermentation adsorption of alcohols can increase the substrate conversion. The fouling of adsorbants by cells and medium components is severe, but this has no measured effect on the adsorption capacity of butanol in at least three successive fermentations. With the addition of some adsorbants it was found that the fermentation was drawn towards the production of butyric and acetic acid.

Notes: Summary In a recycle system in which evaporation is used for ethanol recovery during fermentation, temperature changes of the broth in the loop will occur. These repeated temperature shocks may have an effect on the microbial ethanol production rate. In this study such repeated temperature changes were simulated in a recycle system with ethanol production by baker's yeast. The magnitude of the temperature change, as well as the time of exposure to this change were found to have an effect on the ethanol production rate. A temperature increase from 30°C in the fermentor to 35°C or more in the recycle loop led to a significantly lower ethanol concentration in the broth. This effect became negligible at a short exposure time of 18 s of the yeast to the higher temperature.

Notes: Summary In a butanol batch fermentation the substrate consumption was increased threefold using in-situ product recovery by gas-stripping, in comparison with a control fermentation without product recovery. In a continuous fermentation in-situ recovery led to an increase in the biomass concentration, resulting in a threefold increase in productivity. The substrate consumption was increased by 10%. An external stripper was used as apparatus for the butanol recovery.

Notes: Summary In the butanol/isopropanol batch fermentation the substrate conversion can be raised by simultaneous product recovery using pervaporation with silicon tubing as a membrane.

Notes: Summary In a continuous fermentation of glucose to butanol and isopropanol by immobilized Clostridium beyerinckii cells the products were removed continuously by pervaporation. Both the glucose conversion and the reactor productivity were 65–70% higher than in a continuous fermentation without product removal.