Professional Documents
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BioprocessEngineering
9 Springer-Verlag 1993
Abstract. A simple mathematical model for the interaction of mass transfer, SSF reactions are likely to be more advantageous.
transport with biochemical reaction in solid state fermentations In SSF, the water content is quite low and the microorgan-
(SSF) in static tray type bioreactors under isothermal conditions has ism is almost in contact with gaseous oxygen in the air,
been developed. The analysis has enabled scientific explanations to
a number of practical observations, through the concept of critical unlike in submerged fermentation (SmF). The overall biore-
substrate bed thickness. The model will bemost useful in the predic- action involves the transport of oxygen and water vapour
tion of the concentration gradients as also in efficient design of these into the microbial biomass on the substrate and the bioreac-
bioreactors. tion thereof. Oxygen is consumed and carbon dioxide is
produced through respiration. The reaction involves genera-
List of symbols tion of heat and the transport of he/tt and carbon dioxide
from the interior of the substrate into the gas phase. Because
C g/cm3 Oxygen concentration in the bed of the finite mass and heat transfer resistances, in the reac-
Co g/cma Atmospheric oxygen concentration tion biomass there will be concentration and temperature
C* - Dimensionless oxygen concentration, C/Cg
De cmZ/h Effective diffusivity gradients built up which need to be controlled. In order to
H cm Bed thickness or height design proper SSF reactors with minimum gradients and
Hc cm Critical bed thickness or height highest reaction rates it will be necessary to have suitable
Hm cm Maximum height of zone of zero oxygen concen- mathematical models :for the prediction of the course of the
tration
P~ mg/(g- h) Productivity (Eq. 13) reaction as well as temperature and concentration gradients.
R g/(cms- 11) Biochemical reaction rate The phenomena occurring in the SSF reaction can be
t h Fermentation time visualised as follows:
t* Dimensionless time, D e t / H 2 Initially the inoculum is uniformly mixed with the sub-
X mg/cm 3 Biomass concentration strate which consists of moist solid particles containing
X~ mg/cm3 Maximum biomass concentration
y Dimensionless thickness or height, (y = z/H) starch, cellulose, minerals, etc. The microbial (fungal/bacteri-
y' cm Thickness of zone of zero oxygen concentration al) particles which initially will be on the outer surface of the
(Eq. 12) substrate particles, will slowly grow, multiply and penetrate
y g biomass into the macro- and micropores of the solid. They consume
Yield coefficient
g oxygen
z CITl Bed thickness or height along tray axis the available energy sources e.g. starch hydrolysate. Secreted
Bed void fraction enzymes can also break down the starch and cellulose in the
#max h- 1 Specific growth rate substrate to provide energy. A balanced breakdown may in
fact be necessary for healthy growth, that is, too much hy-
Thiele modulus ~/De Cg Y
drolysed product at any time may give rise to catabolite
repression. The rate of reaction will be controlled by the
kinetics, which depends on the concentrations of substrate,
1 Introduction products, oxygen, temperature and pH in the immediate
vicinity of the microorganisms. Transport effects will govern
Solid State Fermentation (SSF) has recently come to attract the concentration and temperature gradients in the solid
a great deal of scientific attention in view of its untapped mass. Oxygen concentration profiles in the substrate will be
potential for industrial exploitation [6-8]. SSF involves the initially uniform across the bed. But slowly gradients will
growth of microorganisms on moist solid substrate in the develop due to consumption, which are further accentuated
absence of free water and simulates the fermentation reac- by variable rates of reaction caused by the gradients them-
tions that occur in nature. Because of the efficient oxygen selves. As the reaction proceeds, the transport of heat and
256 Bioprocess Engineering 8 (1993)
mass are also affected by the change in the properties (i.e. 02 C02 Heat
effective thermal conductivity, effective diffusivity etc.) of the i I I Externol. firm
solid substrate due to the mycelial growth. The substrate . . . . i ! l_
gets consumed and therefore a reduction of the kinetics oc-
curs, stopping at the stage where the substrate or a critical
nutrient is exhausted. H
In the literature, there is little information on the basic
z=H
engineering aspects of SSF involving transport of heat and
" L
mass in the solid substrate and their interaction on the biore-
action [7, 8]. While the importance of mass transfer has been
emphasised [4], most of the quantitative treatments involv-
ing mathematical models have been concerned with the dif-
fusion of oxygen in mold pellets submerged in liquid [1, 3, 12] Voriotion of 02 concentration
pretties with time
which are not really applicable to SSF involving no free
z=0 Cg
liquid. In view of the absence of information on mathemati-
cal models for SSF, an attempt has been made to develop a
model for mass transfer in a static tray type bioreactor which
is the most common type of SSF, called "Koji" fermentor, in
order to throw more light on the interaction of transport
phenomena with bioreaction in SSF systems and to evolve
guidelines for efficient design if possible. This is the subject
matter of this communication. = eof~T t:0
Zon zero oxygen
concentration
2 Mathematical model Fig. 1. Schematic diagram of SSF tray type bioreactor.
The transport phenomena occurring in a tray type SSF bio- Writing the gaseous oxygen balance equation over an
reactor is schematically shown in Fig. 1. Gaseous oxygen dif- infinitesimal slab of thickness Az and then taking limits as
fuses from the bulk gas over the tray, through the stagnant Az -+ O, we obtain:
film on to the porous substrate bed and is consumed by the
microorganism to yield biomass and product. The carbon ~2C R ~C
dioxide and heat produced by the metabolism travel in the D~ ~z2 Y = e -~-, (1)
reverse way from the interior of the bed to the bulk gas.
Initially there is a uniform concentration of oxygen (atmo- where, D e is the effective diffusivity; e is the void fraction of
sphere) throughout the bed and the same is true of carbon the bed; Y is the biomass yield factor; R is the reaction rate.
dioxide. As the bioreaction starts and progresses, oxygen It is assumed that biomass production rate R, follows the
gets consumed and concentration gradients are built up as logistic equation, as suggested by Ollis [11]:
shown in Fig. 1. Depending on the rate of consumption of
dX ( X )
oxygen as well as the resistance to mass transfer, there can R = d t - = #m.x X I X~ax (2)
be a situation in which the oxygen concentration in the
interior of the bed drops to a very low value. The situation
where #maxis the maximum specific growth rate; Xma x is the
is similar to gas solid noncatalytic reaction in which reaction
maximum biomass concentration.
takes place throughout the solid.
Assuming no mass transfer resistance in the static film of
For the purpose of the model development, the following
gas on the substrate bed and no flux at the bottom end of the
assumptions are made:
bed (bottom plate unperforated), the following initial and
1. Oxygen is the limiting reactant and the energy source boundary conditions can be written:
(sugar/starch) is in excess.
2. The reaction has zero order dependence on oxygen con- Initial conditions: t = 0, C = Ca at all z,
centration but does not proceed in the absence of oxygen
Boundary conditions: z = 0, C = Cg; z = H, ~C = 0 "
N-~ (3)
[91.
3. The substrate bed is isothermal causing neither convec- Non-dimensionalising using
tive mass transfer nor reaction rate enhancement due to
heat. C*=C/Cg; y = z / H and t * = t De/H 2
K. S. M. S. Raghava Rao et al.: A mathematical model for solid state fermentation in tray bioreactors 257
0 i
0 0.25 0.50 0.75 1.00 0 0.25 0.50 0.75 1.00
Dimensientess trey depth y Dimensionless troy depth y
Fig. 3. Oxygen concentration profiles over tray depth y at different Fig. 5, Oxygen concentration profiles over tray depth y at different
times of fermentation for a bed with total height H = 5 cm times of fermentation for a bed with total height H = 9 cm
20 12 h
= 0.80
~ 025
16h Uc
8 go 0.6o
g
g ~6 g
E))
0.50
x 32h~ ~
o
E o./'o
.=-o
0.25 20h
0.20
28h--~\ \ k 2 / , h ~ - 2 2 h y:l.0 /
0 26h \
0.25 0.50 0.75 1.00 10 15 20 25 30 h 35
Dimensientess troy depth y Fermenfotien time
Fig. 4. Oxygen concentration profiles over tray depth y at different Fig. 6. Variation of C* with fermentation time at different locations
times of fermentation for a bed with total height H = 7 cm y in the bed for H = 5 cm
An observation from Figs. 2 - 5 is that when the total bed is due to the fact that as the reaction rate R decreases in the
height H is slightly less than 5 cm, the oxygen concentration decelerating phase (after 28 h, see Table 1), the oxygen con-
at y = 1 just drops to zero giving critical bed height H c. This sumption reduces resulting in an increase in effective oxygen
value is found to be 4.78 cm b o t h through the profiles as well availability at all locations in the bed from 28 h onwards.
as from Eq. (12). The reversal in oxygen concentration is also reported by
In Fig. 6, C* is plotted against fermentation time at differ- R a t h b u n and Shuler [13], during experimental studies on
ent locations in the bed. It can be observed that oxygen Tempeh fermentation in l a b o r a t o r y tray fermenter using
concentrations at all locations within the bed decreases with Rhizopus oligosporus. A point to be noted is that after 28 h,
fermentation time to reach the lowest value at a b o u t 28 h. though the reaction rate is decreasing as indicated by the
Thereafter, a reversal occurs and C* starts increasing. This increase in C*, biomass is forming till 34 h and this forma-
260 Bioprocess Engineering 8 (1993)
1.00 10
%
cm H=10 cm
0.75
8cm
8 6
c
E
o)
>.,
o
~ 0.25
0.50
H=t
b-
/
0 i 0 i
15 25 35 h 10 15 20 25 30 35
Fermentation time Fermentation time
Fig. 7. Variation of C* with fermentation time at the bottom of the Fig. 8. Tray height z' of zero oxygen concentration zone as a func-
tray (y= 1.0) for various bed heights H tion of fermentation time for various bed heights H
200 I f z i i
0 2 4 6 8 10 cm 12 5 Conclusions
Tray height z
Fig. 10. Effect of tray height H on total biomass for the entire Application of the model to practical system requires the
fermentation time of 34 hours values of the transport parameter D e and kinetic parameters
#max and Y which have to be obtained separately. A number
to, tl, ... q , . . . t n. Let Yl be the dimensionless height of the of simplifying assumptions have been made which can be
effective reaction zone where oxygen is available at time t i . considered as limitation of the model. For example, kinetics
Then, productivity is given by: and of the reaction is taken to be zero only with respect to
oxygen and film diffusion effects are ignored. Also, only the
P~= X I - X i - 1 " Yi , (13) growth of biomass is considered to indicate the performance
ti--ti_l of the bioreactor whereas, product formation kinetics will be
highly relevant. Another far reaching assumption is that of
where i = 1 to n. Yi is calculated from Eq. (12).
isothermality in the bioreactor which may simplify the math-
Figure 9 gives the productivity versus fermentation time
ematical analysis but may not be the situation obtained in
for differenet tray thicknesses. From this plot it is clear that
practice. Temperature gradients could be highly important.
as long as the bed height is less than or equal to critical bed
However, with all these limitations, the model is a first seri-
height (that is H_<4.78 cm) the productivity profile is the
ous attempt in quantitatively explaining the interaction of
same. Upto this point, y~ is always unity and there is no zero
transport effects with biochemical reaction in SSF systems
oxygen zone existing in the beds. However, when the bed
and has succeeded in putting a number of facts observed in
height is slightly higher than critical height (H>H~), say
practice in a scientific perspective. Further, the limitations
5 cm, y~ is 0.78 and 0.7 at 26 and 28 hrs respectively. Hence
cited above can be considered to be the field of opportunities
productivity drops at these points as shown in the figure.
for biochemical engineers to pursue further work on the
Once reversal in the zero oxygen concentration zone occurs
engineering aspects of SSF, in order to evolve useful design
at 28-30 h, y~ becomes unity, and the productivity is once
and operational criteria for those systems.
again restored and increases to an even higher value. Simi-
larly, for bed heights of 8 and 10 cm, the zones of zero oxygen
concentration are larger, thus decreasing y~ substantially
Acknowledgements
which in turn, results in lower productivity levels at those
situations, before it is restored due to reversal in C*. To- This work was carried out under the project on Solid State Fermen-
wards the end of the fermentation, the productivity shows a tation (No. BT/TF/25/03/009/89) of Department of Biotechnology,
decrease at all situations, due to the fact that the incremental Government of India, whose financial assistance is gratefully ac-
biomass formation decreases as the bioreaction approaches knowledged. Thanks are also due to Mr. M. M. Krishniah, Chair-
man, Food Engineering, CFTRI for active encouragement.
stationary phase. From this discussion, it is clear that critical
bed height is also the optimal height for a tray fermentor.
This is further substantiated by plotting total biomass
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