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Ch15-Fermentation and Biochemical Engineering
Ch15-Fermentation and Biochemical Engineering
15
Fermentation and biochemical
engineering: principles and applications
Leone Mazzeo, Vincenzo Piemonte*
University Campus Biomedico of Rome, Faculty of Engineering, Rome, Italy
* Corresponding author. e-mail address: v.piemonte@unicampus.it
estimation of the parameters of such models will • Substrate: This is a term used to indicate a
be given. Cell theory, different from enzyme the- reactant involved in an enzymatic reaction.
ory, is mainly based on experimental tests • Active site: This is a specific area of the
followed by the ad hoc formulation of models. enzyme on which the substrate is able to
Engineers always work to make their life easier, connect, giving a substrateeenzyme complex.
and the most-used expression adopted to • Cofactor: This is a nonprotein compound that
describe cell population growth is suspiciously connects with an inactive protein (the
similar to the one used for enzymes. apoenzyme) to form a catalytically active
Finally, a general description of the most- complex (the holoenzyme), commonly called
used reactors will be given and typical enzyme. Cofactors can be made of metal ions
examples of the cell-populated bioreactors will or complex organic macromolecules.
be analyzed. The purpose of this chapter is to • Turnover number: This is a typical index of
transmit a basic knowledge of bioreactor the enzyme’s catalytic activity. It is defined as
modeling and prepare the reader to face future the maximal number of molecules of
bioreactor design work. substrate converted to product per active site
per unit time when the enzyme is saturated
with substrate [2].
2. Enzymes • Units: These are also called units of activity
and are commonly used to express the
Enzymes are globular proteins that act as bio- concentration of enzymes in a solution. A unit
logical catalysts: they are able to increase the rate is defined as the amount of catalytic activity
of a chemical reaction without being consumed per amount of enzyme. The necessity of
and without affecting the thermodynamic defining such an unusual unit measure arises
equilibrium of the reaction itself (respecting the from the impossibility of completely isolating
definition of catalysts) (Fig. 15.2). enzymes from a protein mixture.
Before getting into all the mechanisms and The number of enzymes that is possible to find
related models used to describe the kinetics of in nature is incredibly high and every single one
a catalyzed enzymatic reaction, it is important has a unique and complex chemical structure.
to remind the reader of the terminology used Because of this it has been preferred to classify en-
for this specific topic: zymes by the particular class of reaction in which
FIGURE 15.2 The action of a catalyst (left) lowers the activation energy of the chemical reaction and (right) makes it
possible for molecules with low internal energy to react (right).
4 Lyases Cleavage of CeC, CeO, CeN, or other bonds by elimination, leaving double bonds or rings,
or addition of groups of double bonds
5 Isomerases Transfer of groups within molecules to yield isomeric forms
6 Ligases Formation of CeC, CeS, CeO, and CeN bonds by condensation reactions coupled to
cleavage of ATP or similar cofactor
they are involved. Six main classes of reactions plays a critical role in the enzymatic action, devel-
and six types of enzymes have been identified oping its selectivity for a specific substrate.
and are reported in Table 15.1. How enzymes increase the rate of a biochem-
ical reaction is still a research topic, but two pos-
itive effects have been highlighted:
2.1 Enzyme kinetics
1. Proximity effect: This is the ability of the
Several investigations into the mechanisms enzyme to “collect” the substrates in its active
that enzymes adopt to catalyze biological reac- site.
tions have been done. All the results of such 2. Orientation effect: The substrates in the
studies agree on the existence of a substratee active site are oriented in the proper way to
enzyme complex as the first step of the enzymatic interact with each other.
reaction: the substrate links with the active site of
the enzyme. As is easy to see in Fig. 15.3, the The design of any type of reactor requires
three-dimensional configuration of the enzyme knowledge of the kinetics expression that
FIGURE 15.3 Focus on the substrateeenzyme complex. In this picture, the enzyme hexokinase, which is responsible for
transforming glucose and ATP into glucose 6-phosphate and ADP, is represented.
describes the rate of the reaction. With the 2. The substrateeenzyme complex releases the
growing utilization of enzymes in the medical, product. This step is assumed to be
pharmaceutical, and industrial fields, the neces- irreversible:
sity of finding a simple way, in line with all the
experimental data, to reproduce biological reac- k2
ES ! E þ P: (15.2)
tions catalyzed by enzymes is becoming more
and more important. As usual, many assump- Since every step of the mechanism is consid-
tions and exceptions hide behind every formula; ered an elementary reaction:
for this reason, in the following paragraphs a dp ds
schematic guide is given, to prevent confusion v¼ ¼ ¼ k2 ðesÞ; (15.3)
dt dt
between all the different cases and their range
of application. se k1
¼ ¼ Km ; (15.4)
ðesÞ k1
2.1.1 MichaeliseMenten kinetics
e þ ðesÞ ¼ e0 : (15.5)
From the pieces of information known about
enzymes at the time, Michaelis, Menten, and Here, s, e, and (es) indicate the concentrations of the
Henri in 1902 proposed the following mecha- compounds S,E, and ES, respectively, while the
nism of reaction and its related model, from parameter Km is the dissociation constant and e0
which they derived (Fig. 15.4) the famous is the initial concentration of the enzyme. Rear-
MichaeliseMenten kinetics expression: ranging all the equations it is easy to obtain the
MichaeliseMenten rate equation plotted in Fig. 15.5:
1. The substrate links with the enzyme, forming
the substrateeenzyme complex. This step is
s
supposed to be in equilibrium: v ¼ vmax ; vmax ¼ k2 e0 : (15.6)
Km þ s
k1
S þ E # ES: (15.1) Another way to describe the same situation
k1 was developed by Briggs and Haldane. They
FIGURE 15.4 A schematic of the hydrolysis of sucrose as an example of a MichaeliseMenten reaction mechanism.
FIGURE 15.5 (A) Plot of the MichaliseMenten equation. (B) MichaeliseMenten kinetics of the chimeric enzyme CelA--
SSO1949-CelA at pH 3 and 80 C, in which the velocity has been divided by the constant enzymatic concentration [4].
solved numerically the set of equations relative of them are mainly based upon a linear transfor-
to the reaction scheme given earlier (Eqs. 15.1 mation of Eq. (15.4) (Table 15.2). The most
and 15.2): important linearization methods are the ones
8 indroduced by Langmuir and Lineweaver-Burk.
>
> ds
>
> v ¼ ¼ k1 se k1 ðesÞ An example of the estimation of Michaelise
>
> dt
>
> Menten parameters is given: sago starch hydro-
< dðesÞ lysis using amyloglucosidase derived from
¼ k1 se ðk1 þ k2 ÞðesÞ : (15.7)
> dt
> Aspergillus niger [6,7].
>
>
>
> e þ es ¼ e0 In general, the Langmuir plot appears to be
>
>
: more accurate than LineweavereBurk. This is
I:C: sð0Þ ¼ s0 ðesÞð0Þ ¼ 0 because the maximum experimental error
From the results shown in Fig. 15.6 it is notice-
able that if the ratio e0/s0 is low enough, an
approximation of quasiesteady state can be
done, setting:
dðesÞ
¼ 0: (15.8)
dt
After a few calculations it is easy to find that
even when imposing the quasi-steady-state con-
dition the expression of MichaeliseMenten ki-
netics it is obtained again. This time Km ¼
k1 þk2
k1
from the model, but nothing changes
from the experimental point of view: the same
equation can be used to fit experimental data
and describe the substrate consumption rate.
Several strategies have been developed to FIGURE 15.6 Result plot of the set of Eq. (15.5). In this
evaluate MichaeliseMenten parameters, and all case the ratio e0/s0 is low enough that after a short time the
quasi-steady-state condition, Eq. (15.6), is established.
FIGURE 15.7 Typical feedback inhibition scheme. The product of every reaction constitutes a (intermediate) substrate for
the following one involving another enzyme. The end product inhibits the activity of the first enzyme involved in the reaction
chain.
TABLE 15.3 Typology of inhibition attack and related expression of the MichaeliseMenten constants.
Model
a
Remember that for the noncompetitive type, the inhibitor and the substrate do not influence each other as to affinity for the complex with the enzyme. For
this reason the dissociation constants are just Ks and Ki.
FIGURE 15.8 Qualitative overview by means of LineweavereBurk plot of different cases of inhibition [9]. (A) Competitive
inhibitor, (B) noncompetitive inhibitor, (C) uncompetitive inhibitor, (D) mixed inhibitor.
FIGURE 15.10 Activity detection of two commercial b-galactosidases (Lactozym and Maxilact) depending on pH. Two
types of models have been used to fit the data (M1 and M2). Further information in [12].
best one by means of an experimental data system consisting of a liquid with dispersed
fitting. What is certain is that the activity of gas bubbles, a liquideliquid system in which
the enzyme will decrease with increase in the immiscible fluids are present, or a three-phase
temperature. system (liquideliquidegas).
As represented in Fig. 15.12 four phases are where x is the cell mass per unit culture volume,
typically present in cell growth: s is the concentration of the limiting nutrient, and
mobs is the observed specific growth rate of the cells,
• Lag phase: The cells need an amount of time to
which is a constant since all substrates necessary
synthesize the cofactors (coenzymes, ions) and
for growth are present in excess. When there is a
enzymes able to metabolize the nutrient, so
limiting nutrient present, mobs ¼ f(s), where s is
when a new medium is applied on the culture
the concentration of the limiting nutrient. All
or when the cells are transferred to a new
the phenomena that may influence the cell
environment the lag phase occurs. Special care
mass growth are included in mobs(s). In this chap-
must be taken when a cell population is
ter only unstructured and unsegregated models
transferred into a larger volume of medium
will be used.
since the outward diffusion of cofactors into
the new medium may cause a delay in cellular • Stationary phase: In this phase the rate of
growth. Sometimes it is possible to observe production of newborn cells is equal to the rate
multiple lag phases due to the exhaustion of of death and the net quantity of cells does not
one nutrient and the reorganization of the cell change. It happens that the nutrients are
to absorb its carbon supply from another almost finished and the living population uses
source. This phenomenon is called diauxic the components of dead cells to sustain itself.
growth (Fig. 15.13). • Death phase: This is usually an exponential
• Logarithmic phase: Also called exponential decay in the number of living cells due to the
growth, because it has an exponential trend, exhaustion of the nutrient resources.
this is the phase in which the cell biomass
simply grows. The description of this
phenomenon is often accomplished by means
of an unstructured and unsegregated model
3.5 Monod growth kinetics
in which the cell mass generation rate is: It has already been mentioned that the rate of
biomass generation for an unstructured and un-
segregated model is usually written as Eq.
ðrx Þ ¼ mobs x; (15.15) (15.15). The parameter mobs is usually expressed
as a combination of parameters that may influ-
ence the generation of biomass and, in the pres-
ence of a limiting nutrient, it may be written as:
mobs ðsÞ ¼ mðsÞ þ k: (15.16)
Here k represents a generic kinetic constant of
other possible mechanisms having an impact
on biomass growth. For example, in the case of
cellular death by mechanical agitation occurring
in the reactor, k < 0 (called the death kinetic con-
stant) is introduced to consider this phenome-
non. Several ways are used to express the
parameter m(s), the specific growth rate of cells.
The most common one is the Monod equation:
mmax s
mðsÞ ¼ : (15.17)
FIGURE 15.13 Typical cellular diauxic growth plot. Ks þ s
FIGURE 15.14 An example of using the Monod expression to model the behavior of the cyanobacterium Synechocystis sp.
PCC6803 having as nitrogen as the limiting nutrient. Here for msyn,LI is identified the maximum specific rate modified by the
effect of LI (light irradiation) [15].
Products may belong to two different classes It is common to relate the production forma-
of metabolites: tion rate and the amount of biomass as follows:
Here S is the carbon source, N the nitrogen source, X the cell mass, and P the product; s, n, o, w, and e are the stoichiometric coefficients of the
reactions; Mx, Mp, and Ms are the molecular weights of the cells, products, and substrates, respectively. It is important to remember that the
“true” yield model is related only to describe the production of a secondary metabolite. For further details see Ref. [19].
a
Material balances are assumed to be for a constant volume batch fermentor. For the equations in the model obtained from the estimation of the “true” yield
coefficient, there is assumed to be no cell death related to the mechanical agitation in the reactor. See Chapter 4 for details.
entering of coming out from it, but it can • The plug flow reactor (PFR) is an open
eventually exchange heat with the system. The fluid passing through a PFR has a
environment. An ideal BSTR has the property flat velocity profile; in this sense a PFR is an
of perfect fluid mixing. It represents the ideal reactor. This condition happens
typical case of a cell culture. typically when a fluid moves through a pipe
• The fed-BSTR is a semi-open system; in fact, with a sufficiently large Reynolds number
mass can enter but not exit the reactor. It is an (Re > 2100).
enhancement of the closed batch process in
which the substrate is added in increments as
the fermentation progresses. An ideal fed- 5. Typical industrial fermentation setup
BSTR has the property of perfect fluid
mixing. Two recurrent industrial biological reactor
• The continuous stirred tank reactor (CSTR) configurations will be analyzed in this section:
is an open system. An ideal CSTR has the the chemostat and the aerobic reactors. In the
property of perfect fluid mixing. A classical first typology, the mathematical dynamic model
CSTR bioreactor is individualized in the used to describe it helps in understanding the
chemostat configuration, in which a sterile possibility of the occurrence of unstable working
nutrient solution is added to the bioreactor sates of the reactor; in the second typology, oxy-
continuously and an equivalent amount of gen must be supplied to the cell population:
converted nutrient solution with particular attention is given to the transfer rate
microorganisms is simultaneously taken out expression of oxygen from the gaseous phase
of the system [20]. to the liquid phase.
TABLE 15.8 Equations used for a general description of the principal ideal
reactors.
Equations System
VR ¼ constant
dx
dt
¼ ðrx Þ
ds
dt
¼ ðrs Þ
dp
dt
¼ ðrp Þ
dðVR xÞ
dt
¼ ðrx ÞVR þ QðtÞxf
dðVR sÞ
dt
¼ ðrs ÞVR þ QðtÞsf
dðVR pÞ
dt
¼ ðrp ÞVR þ QðtÞpf
VR ¼ constant
Q(x xf) ¼ (rx)VR
Q(s sf) ¼ (rs)VR
Q(p pf) ¼ (rp)VR
The results of the system of Eqs. (15.24) where the addition flux term qtO2
expresses the
e(15.25) and the productivity are plotted in the amount of oxygen transferred from the gas
graph shown in Fig. 15.16. phase, given by breathed air, to the liquid phase.
The evaluation of qtO2 is given according to the
mass transfer film theory (Fig. 15.17), which
gives:
5.2 Aerobic reactors: cellular respiration
Organisms may be divided into three main qtO2 ¼ KOL aðCO2 CO2 (15.33)
classes depending on their ability to live with 2
or without oxygen consumption [23]: L
Here a is the gas bubble surface to reactor
L3
• Obligate anaerobes: These are prokaryotic liquid volume ratio, KOL is the overall liquidegas
microorganisms (Clostridium sp., the soil mass transfer coefficient, and CO2 is the oxygen
bacteria Actinomyces, and the methanogenic concentration in the liquid phase in equilibrium
bacteria) for which molecular oxygen is a
toxic substance.
• Obligate aerobes: These are organisms that
require molecular oxygen as the terminal
oxidizing agent to fulfill their energetic needs,
such as humankind.
• Facultative anaerobes: These are organisms
that are able to grow either in the presence or
in the absence of oxygen (e.g., Saccharomyces
cerevisiae, the “brewer’s yeast”).
It is obvious that an amount of oxygen must
be delivered to the reactor if it is necessary for
the survival of the cell population. In such case,
oxygen consumption is typically coupled FIGURE 15.17 Film theory sketch: visualization of the
directly to the amount of carbon source substrate gaseliquid interphase and the local mass transfer coefficients
consumed (commonly glucose). kG, for the gaseous film, and kL for the liquid one.
FIGURE 15.18 Experimental data of the cellular specific growth rate for the sulfur oxidizing bacteria Acidithiobacillus thi-
ooxidans. (A) The concentration of oxygen in the liquid is kept constant at a value at which it is no longer considered a limiting
nutrient and the dependence of the specific grow rate upon the concentration of sulfide in the liquid has been detected. (B) With
a constant concentration of sulfide in the liquid, the dependence of the specific growth rate upon the concentration of oxygen in
the liquid has been detected [24].
Eq. (15.37) and, in fact, from the study KO2 ¼ materials belonging to the food industry
1:10 mg=L and graph (A) of Fig. 15.18 was (such as sugar cane, sorghum, and corn).
made with CO2 y6 mg=L. • Second-generation bioethanol was developed
to substitute food-based feedstock with raw
materials that are almost all waste products.
Five classes of such raw materials may be
6. Bioethanol production defined: (1) wood residues, (2) municipal solid
waste, (3) agriculture residues, (4) dedicated
A typical example of employing both enzy- energy crops, and (5) microalgal biomass.
matic and cellular technologies is the production
of bioethanol. Fossil fuel depletion has become a The bioethanol production process is
great concern as the world population is composed of three macrounits common to all
increasing at an alarming rate. Current concerns the types of raw materials:
such as global warming, depletion of fossil fuels, 1. Pretreatment: It is necessary to break the cell
and increasing price of petroleum-based fuels wall membrane of the biomass and permit the
have forced the search for alternative and cost- release of all the cell contents (carbohydrates
effective energy sources with fewer greenhouse for bioethanol production, lipids for biodiesel
gas emissions. Research into the development production). It is extremely important, since it
of renewable and sustainable fuels has recog- affects the efficiency and consequently the
nized bioethanol as a viable alternative to fossil cost of the whole process. Many different
fuels, owing to its low toxicity, biodegradability, pretreatment techniques have been
and ability to effectively blend with gasoline developed (Fig. 15.19) and the most
without any engine modifications [25]. appropriate one to adopt depends on the
Depending on the raw materials used for the particular biomass selected and the
bioethanol production, two main classes of configuration of the plant.
such product may be identified: 2. Hydrolysis: Starch, lignocellulose, or, better,
• First-generation bioethanol is made via a polymeric carbohydrates and polyphenolic
traditional production approach using raw lignin are not directly fermentable by most
FIGURE 15.19 Classification of cell pretreatment methods [26]. EFAC, Electroflotation by alternating current.
the ethanol production yield. In such a way the liquid sugar-rich phase, which sugar concentra-
issue involving S. cerevisiae, commonly unable tion is monitored by the evaporator, directed to
to ferment pentose sugars like xylose and arabi- the fermentor. The fermentation bioreactor is
nose, was overcome [28]. Since in such case a inoculated from an inoculum seed train. This is
contemporaneous fermentation of different required to avoid the shock of inserting a cell cul-
types of monomeric sugars takes place, the pro- ture into a new or bigger volume environment,
cesses involving this technique are called simul- which may cause undesired behaviors of the cells.
taneous saccharification and cofermentation or Finally, the content of the fermentation reactor is
separate hydrolysis and cofermentation, collected into a storage tank, which permits all the
depending on whether the SSF or SHF configura- following units to work continuously.
tion is chosen, respectively.
FIGURE 15.21 Example of a process flow diagram for the production of bioethanol.
Year Event
substances in the design, manufacture, and of bio-based reactors was already more than 200
application of chemical products. It is noticeable [23]. This highlights how the potentialities of
how the utilization of bioreactors fits perfectly such technology are well known and how, for
into such definition: in fact, such units operate the near future, its rapid development is ex-
at low temperature and pressure (typically pected, in line with the ideal of green chemistry.
T ¼ 37 C and P ¼ 1 atm), reducing the consump-
tion of energy in the plants, avoiding the waste
of chemicals, and guaranteeing safer working
conditions (Fig. 15.22). List of abbreviations and acronyms
According to some data on the year 2013, the SHF separate hydrolysis and fermentation
number of companies involved in the utilization SSF simultaneous saccharification and fermentation
FIGURE 15.22 An example of the substitution of a conventional scrubber unit for the removal of H2S from a biogas stream
with a biological reactor. The bacteria Acidithiobacillus thiooxidans are responsible of the oxidation of H2S to obtain living energy.
List of symbols qtO2 flux of oxygen, from the gaseous phase to the liquid
phase, per unit volume of liquid in the reactor
R gas constant
a gas bubble surface to reactor liquid volume ratio
(rp) rate of product formation per unit volume of liquid
CO2 concentration of oxygen in the liquid
in in the reactor
CO concentration of oxygen entering a CSTR reactor
2
(Lrs) rate of substrate consumption per unit volume of
CO concentration of oxygen in the liquid phase in
2
liquid in the reactor
equilibrium with the bulk of the gas phase
(rx) rate of biomass formation per unit volume of liquid
c maintenance term in Herbert model
in the reactor
D dilution rate
ðLrO2 Þ rate of oxygen consumption per unit volume of
Dmax maximum dilution rate
liquid in the reactor
E enzyme element in the reaction formula
S substrate in the reaction formula
ES substrateeenzyme complex in the reaction formula
s substrate concentration
EI inhibitoreenzyme complex in the reaction formula
sf feed substrate concentration
EIS inhibitoresubstrateeenzyme complex in the reac-
T absolute temperature
tion formula
u mean velocity in the PFR reactor
Ea active enzyme element in the reaction formula
VR volume of liquid in the reactor
Ed denatured enzyme element in the reaction formula
X biomass in the reaction formula
Ei inactive enzyme element in the reaction formula
x biomass concentration
e enzyme concentration
xf feed biomass concentration
e0 initial enzyme concentration
YG “true” growth yield: stoichiometric factor of the
(es) substrateeenzyme complex concentration
reaction that produces biomass from substrate
DGd denaturation Gibbs free energy variation
YP “true” product yield: stoichiometric factor of the
HO2 ;mix Henry constant of oxygen in a mixed liquid solution
reaction that generates product from substrate for
I inhibitor in the reaction formula
secondary metabolites
i inhibitor concentration
Yp/s observed product yield formation
K1 enzyme first reduction equilibrium constant
Yx/s observed biomass yield formation
K2 enzyme second reduction equilibrium constant
yL fraction of active enzymes
Kd equilibrium constant of enzyme inactivation with
yO2 P oxygen partial pressure
temperature
Ki gas inhibitoreenzyme dissociation constant
Km MichaeliseMenten dissociation constant
app
Km apparent Michaelis-Menten dissociation constant
KOL overall liquidegas mass transfer coefficient Greek symbols
KP product concentration that reduces to one-half the
cellular specific growth rate m(s) biomass specific growth rate
KS substrate concentration at which the cellular specific mmax maximal biomass specific growth rate
growth rate is half its maximum mobs observed biomass specific growth rate
KO2 oxygen Monod constant n reaction rate
k1 kinetic constant for the production of the nmax maximum reaction velocity
substrateeenzyme complex napp
max maximum apparent reaction velocity
kL1 kinetic constant for the dissociation of the
substrateeenzyme complex
k2 kinetic constant for the formation of the product
kG gas mass transfer coefficient
References
kL liquid mass transfer coefficient [1] K.Chojnacka, Fermentation Products, Chemicalengin-
m maintenance term in Pirt’s model eering and chemical process technology, Vol. V.
P product element in the reaction equation [2] R.H. Garret, C.M. Grisham, Biochemistry, 1999.
p product concentration [3] D.L. Nelson, M. M. Cox, Lehninger Principles of
pf product feed concentration Biochemistry, W.H. Freeman & Co.
Q volumetric flow rate [4] K. Kufner, G. Lipps, Construction of a chimeric ther-
q(s) observed specific consumption rate of substrate moacidophilic beta-endoglucanase, BMC Biochemistry
qp observed product specific production rate 14 (2013) 11.