WO2008102249A1 - Bioreactor for continuous production of micro-organisms and products of micro-organisms by solid state fermentation - Google Patents

Bioreactor for continuous production of micro-organisms and products of micro-organisms by solid state fermentation Download PDF

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Publication number
WO2008102249A1
WO2008102249A1 PCT/IB2008/000397 IB2008000397W WO2008102249A1 WO 2008102249 A1 WO2008102249 A1 WO 2008102249A1 IB 2008000397 W IB2008000397 W IB 2008000397W WO 2008102249 A1 WO2008102249 A1 WO 2008102249A1
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Prior art keywords
bioreactor according
vertical
radial arms
bioreactor
reaction vessel
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Application number
PCT/IB2008/000397
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French (fr)
Inventor
Mark Mccormick
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Mark Mccormick
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Publication of WO2008102249A1 publication Critical patent/WO2008102249A1/en

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    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M21/00—Bioreactors or fermenters specially adapted for specific uses
    • C12M21/14—Bioreactors or fermenters specially adapted for specific uses for producing enzymes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
    • B01F27/05—Stirrers
    • B01F27/11—Stirrers characterised by the configuration of the stirrers
    • B01F27/119—Stirrers with rigid wires or flexible rods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
    • B01F27/80—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a substantially vertical axis
    • B01F27/82—Pan-type mixers, i.e. mixers in which the stirring elements move along the bottom of a pan-shaped receptacle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F29/00—Mixers with rotating receptacles
    • B01F29/80—Mixers with rotating receptacles rotating about a substantially vertical axis
    • B01F29/83—Mixers with rotating receptacles rotating about a substantially vertical axis with rotary paddles or arms, e.g. movable out of the receptacle
    • B01F29/835—Pan-type mixers, i.e. having stirrers moving along the bottom of a pan-shaped receptacle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F31/00—Mixers with shaking, oscillating, or vibrating mechanisms
    • B01F31/10—Mixers with shaking, oscillating, or vibrating mechanisms with a mixing receptacle rotating alternately in opposite directions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F33/00—Other mixers; Mixing plants; Combinations of mixers
    • B01F33/80—Mixing plants; Combinations of mixers
    • B01F33/81—Combinations of similar mixers, e.g. with rotary stirring devices in two or more receptacles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F33/00—Other mixers; Mixing plants; Combinations of mixers
    • B01F33/80—Mixing plants; Combinations of mixers
    • B01F33/81—Combinations of similar mixers, e.g. with rotary stirring devices in two or more receptacles
    • B01F33/811—Combinations of similar mixers, e.g. with rotary stirring devices in two or more receptacles in two or more consecutive, i.e. successive, mixing receptacles or being consecutively arranged
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M21/00—Bioreactors or fermenters specially adapted for specific uses
    • C12M21/16—Solid state fermenters, e.g. for koji production
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M23/00—Constructional details, e.g. recesses, hinges
    • C12M23/02—Form or structure of the vessel
    • C12M23/04—Flat or tray type, drawers
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M27/00—Means for mixing, agitating or circulating fluids in the vessel
    • C12M27/10—Rotating vessel

Definitions

  • the invention relates to a bioreactor which enables the production of industrially useful micro-organisms and products of micro-organism (e.g. enzymes) for use in the fields of, but not limited to, fuel ethanol production, animal feed production, paper production, textile production, wastewater treatment, environmental remediation and agriculture.
  • micro-organism e.g. enzymes
  • a bioreactor is defined as a vessel in which optimum conditions for the production of a specific product of micro organism(s) are maintained.
  • Solid state fermentation is defined as the cultivation of micro organisms on a solid substrate in the absence of free water. The technique of solid state fermentation is especially well suited for the production of fungi and fungal products.
  • the most common bioreactor configurations for solid state fermentation are the tray reactor, perforated bag and the Koji process in which microbes are cultivated on solid substrates in agitated bins. These are all batch processes.
  • Optimal productivity of micro organisms or products of micro organisms is obtained by creating in the bioreactor the specific physical and chemical conditions required during the distinctly different microbial growth phases.
  • Biocon Ltd describes a tray reactor for solid state fermentation.
  • the bioreactor vessel is in the form a cylinder the axis of which is vertical.
  • Solid substrate is placed on horizontal trays. Physical and chemical parameters are precisely monitored and controlled. Only batch mode of operation is described.
  • HOFER BIOREACT GMBH describes a device for the continuous preparation of defined enzyme and metabolite mixtures by solid-phase culturing of stable microbial mixed populations.
  • the bioreactor is in the form of a cylinder the axis of which is horizontal. Movement of the solid substrate is effected by a screw having the same horizontal axis as the cylinder.
  • the device does not provide a specific means to subdivide the solid substrate into masses having a sufficiently small volume to enable the precise control physical and chemical parameters. Consequently, it is not possible to optimize the moisture level, gas (e.g. oxygen) concentration, temperature, pH and media composition at many points in the solid substrate. As a result, the ability to optimize fermentation processes is reduced. Moreover, the power and mechanical strength requirements to drive the horizontal screw are significant and costly to meet.
  • the present invention relates to the construction and operation of a bioreactor for the continuous production of micro organisms and products of micro organisms by solid state fermentation or solid phase culture.
  • the bioreactor of the invention may be summarized in the following items, which will be explained hereinafter:
  • a bioreactor for the continuous production of microorganisms and products of micro-organisms by solid state fermentation comprising a vertical, cylindrical reaction vessel having a raw material inlet and a product recovery outlet and containing a vertical central tube extending from the top to the bottom along the vertical axis of said vertical cylindrical reaction vessel; radial arms attached to said vertical central tube or to said vertical cylindrical reaction vessel ; and rotation means to rotate said vertical central tube or said vertical cylindrical reaction vessel around the vertical axis of said vertical cylindrical reaction vessel.
  • Fig. 1 is a profile view showing a bioreactor according to the invention
  • Fig. 2 is a profile view of the bioreactor of the invention, wherein the outer bioreactor shell is removed;
  • Fig. 3a is top plan view of a representative tray and arms
  • Fig. 3b is a top plan view of preferred tray
  • Fig. 3c is a side cross-sectional view of the tray of Fig. 3b;
  • Figure 4 is a perspective view of arms attached to the central tube ; and Figure 5 is a front view of arms attached to central tube and positioned to form a helix.
  • the bioreactor comprises a fermentation vessel 1, growth media tanks 2, solid matrix feed hopper 3 and inlet air filter 4.
  • the fermentation vessel is comprised of an outer shell wall in the form of a cylinder.
  • the ends of the cylinder are capped. Openings in the caps are provided for the continuous introduction of solid substrate at the top of the vessel and continuous withdrawal of the fermentation products from the bottom of the vessel.
  • the bioreactor of the invention does not comprise horizontal trays.
  • the bioreactor of the invention then preferably comprises horizontal arms having the form of a cylinder or a plane.
  • the bioreactor comprises horizontal trays.
  • the horizontal trays 5 are in form of disks having the same diameter as the inner diameter of the fermentation vessel 1 and are fixed to the inside of the vessel such that the surface of each tray is perpendicular or nearly perpendicular to the longitudinal vertical axis of the vessel.
  • the series of trays are positioned, their faces on parallel planes, from one end to the other end of the vessel and the spacing between the trays is between 1 and 500 mm.
  • each tray 5 contains slits or through holes 14 that are not located in the centre of the tray 5.
  • each tray 5 is preferably cut along radial lines extending from the circumference of the tray 5 to a point near the central hole 11 of the tray 5 to form one or several tray sections 14a.
  • the tray sections 14a formed by cutting along the radial lines are inclined. The inclination is preferably approximately 5 degrees downward from the plane of the tray.
  • Each tray 5 contains one hole 11 located in the centre of the tray.
  • central tube 7 has approximately the same length as the fermentation vessel 1 and a much smaller diameter and is positioned along the longitudinal axis of the fermentation vessel 1 in the holes 11 located in the centre of the trays 5.
  • the arms 6 approximately have the same length as the radius of the circular trays less the radius of the central tube 7 and are attached to the central tube 7 such that movement of the arms 6 relative to the trays 7 provides effective translocation of the fermented material across the surface of the tray 5.
  • Additional holes 14 are provided in the tray for the passage of the solid material.
  • At least one stationary arm is preferably located between each pair of circular trays 5 and the arms 6 are positioned so as to maximize the agitation of the matrix material, the efficient use of the volume of the fermentation vessel 1 as well as the transfer of the matrix material through the fermentation vessel 1 in the manner of plug flow.
  • the radial arms 6 or stationary additional arms have a scraper that contacts the tray. The relative movement of the scraper to the tray then displaces the matter on the tray.
  • Each radial arm 6 and/or stationary additional arm may then be paired with one tray.
  • each arm is between 20 and 1000 mm.
  • the length of each arm is equal to the distance from the vessel outer wall to the central shaft less between 2 and 50 mm.
  • the height of the arms is between 10 and 500 mm.
  • Continuous flow of solid matrix material is due to the force of gravity and the action of moving arms or trays on the solid matrix material.
  • Flow of the solid matrix material in the downward direction is between arms, through additional holes and/or inclined tray sections in the horizontal trays.
  • the rate of downward flow of the solid matrix material is controlled by contact with the arms or the trays .
  • Control of gas composition, temperature, humidity and growth media feed may be effected by the use of sensors and actuators positioned on the arms, trays and vessel wall.
  • Process monitoring probes may be attached at appropriate positions in the bioreactor.
  • Process control actuators may be attached at appropriate positions in the bioreactor.
  • Process monitoring and control may be coordinated by specific process logic and a controller.
  • the bioreactor volume may be divided into logical sectors composed of a subset of the total number of probes and actuators.
  • Regions comprising a certain number of probes and actuators
  • inlet or outlet valves may be defined within the bioreactor for the purpose of organizing data for continuous monitoring and control of temperature, humidity, oxygen level and other parameters important for optimising productivity.
  • the bioreactor can be equipped with a Clean-In-Place (CIP) system.
  • CIP Clean-In-Place
  • Mechanical power to rotate the bioreactor components may be provided by electric motors or pneumatic devices.
  • the central bioreactor tube 7 can be rotated in a clockwise and counter-clockwise direction while the outer vessel wall is immobile.
  • the vertical cylindrical reaction vessel 1 can be rotated in a clockwise and counter-clockwise direction while the central bioreactor tube 7 is immobile.
  • the trays 5 are attached to the internal wall of the cylindrical vertical vessel, and conversely.
  • the stationary additional arms are attached to the immobile, part, i.e. either the central tube or to the internal wall of the vertical cylindrical reaction vessel.
  • Inlet air is preferably filtered to prevent entry of contaminant microbes.
  • a means of removing exhaust gas 10 may be provided at the top of the vessel 1.
  • Means for the control of solid matrix flow rate, PLC and relevant process monitoring and control devices and a clean- in-place system may also be provided.
  • Means for cooling and/or heating the reaction vessel may also be provided.
  • a means of controlling the temperature by convection or evaporative cooling may also be provided.
  • Tubing to carry inlet gas may be placed on a pathway through the central tube and above mentioned arms .
  • Tubing to carry exit gas may be placed on a pathway through the central tube and above mentioned arms .
  • Tubing to carry growth media and water may be placed on a pathway through the central tube and above mentioned arms .
  • the radial arms may be provided with nozzles to spray water or inject air into the vessel.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Bioinformatics & Cheminformatics (AREA)
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  • Genetics & Genomics (AREA)
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Abstract

The invention relates to the construction and operation of a bioreactor for the continuous production of micro organisms and products of micro organisms by solid state fermentation. This bioreactor comprises a vertical, cylindrical reaction vessel (1) having a raw material inlet (8) and a product recovery outlet (9) and containing a vertical central tube (7) extending from the top to the bottom of said vertical cylindrical reaction vessel (1); radial arms attached to said vertical central tube (7) or to said vertical cylindrical reaction vessel (1); and rotation means to rotate said vertical central tube (7) or said vertical cylindrical reaction vessel around the vertical axis of said vessel (1). The bioreactor of the invention can be used for the production of catalysts which can be fed directly to a reactor for hydrolysis, for the treatment of wastes or for whitening of paper pulp.

Description

0397
Bioreactor for continuous production of micro-organisms and products of micro-organisms by solid state fermentation
FIELD OF THE INVENTION
The invention relates to a bioreactor which enables the production of industrially useful micro-organisms and products of micro-organism (e.g. enzymes) for use in the fields of, but not limited to, fuel ethanol production, animal feed production, paper production, textile production, wastewater treatment, environmental remediation and agriculture.
BACKGROUND AND PRIOR ART OF THE INVENTION
A bioreactor is defined as a vessel in which optimum conditions for the production of a specific product of micro organism(s) are maintained. Solid state fermentation is defined as the cultivation of micro organisms on a solid substrate in the absence of free water. The technique of solid state fermentation is especially well suited for the production of fungi and fungal products. The most common bioreactor configurations for solid state fermentation are the tray reactor, perforated bag and the Koji process in which microbes are cultivated on solid substrates in agitated bins. These are all batch processes.
Optimal productivity of micro organisms or products of micro organisms is obtained by creating in the bioreactor the specific physical and chemical conditions required during the distinctly different microbial growth phases.
It is known that higher productivity of some micro organisms and products of micro organisms can be obtained by solid state fermentation than by submerged (liquid) fermentation. Nevertheless, biotechnologists usually prefer submerged fermentation mainly due to the ease of maintaining homogeneous physical and chemical conditions in the bioreactor .
It is well known to those skilled in the art that the ability to control moisture levels, introduction of feed gases such as oxygen, and the evacuation of heat and waste gases is an important factor in the productivity of solid state fermentation processes. Technical solutions that permit the control of these factors are essential to successfully scale-up solid phase fermentation processes.
In US Patent 6,664,095, Biocon Ltd describes a tray reactor for solid state fermentation. The bioreactor vessel is in the form a cylinder the axis of which is vertical. Solid substrate is placed on horizontal trays. Physical and chemical parameters are precisely monitored and controlled. Only batch mode of operation is described.
In US patent application 2002/0031822, van der WeI, Oostra, Rinzema, and Timmer describe a bioreactor for solid state fermentation in the form of a cone. The axis of the cone is vertical. Agitation and prevention of compaction is effected by a screw the axis of which is the same as that of the cone. Only batch mode of operation is described.
A continuous process is desirable for integration with industrial systems including hydrolysis of lignocellulosic biomass for fuel ethanol production, paper pulp whitening and wastewater treatment. In WO2004/113490, HOFER BIOREACT GMBH describes a device for the continuous preparation of defined enzyme and metabolite mixtures by solid-phase culturing of stable microbial mixed populations. The bioreactor is in the form of a cylinder the axis of which is horizontal. Movement of the solid substrate is effected by a screw having the same horizontal axis as the cylinder. The device does not provide a specific means to subdivide the solid substrate into masses having a sufficiently small volume to enable the precise control physical and chemical parameters. Consequently, it is not possible to optimize the moisture level, gas (e.g. oxygen) concentration, temperature, pH and media composition at many points in the solid substrate. As a result, the ability to optimize fermentation processes is reduced. Moreover, the power and mechanical strength requirements to drive the horizontal screw are significant and costly to meet.
SUMMARY OF THE INVENTION The present invention relates to the construction and operation of a bioreactor for the continuous production of micro organisms and products of micro organisms by solid state fermentation or solid phase culture. The bioreactor of the invention may be summarized in the following items, which will be explained hereinafter:
1. - A bioreactor for the continuous production of microorganisms and products of micro-organisms by solid state fermentation, comprising a vertical, cylindrical reaction vessel having a raw material inlet and a product recovery outlet and containing a vertical central tube extending from the top to the bottom along the vertical axis of said vertical cylindrical reaction vessel; radial arms attached to said vertical central tube or to said vertical cylindrical reaction vessel ; and rotation means to rotate said vertical central tube or said vertical cylindrical reaction vessel around the vertical axis of said vertical cylindrical reaction vessel.
2.- Bioreactor according to item 1, wherein said radial arms are attached to said vertical central tube and said rotation means are means for rotating said vertical central tube.
3.- Bioreactor according to item 2, further comprising horizontal trays fixed to the inside of said vertical reaction vessel, each tray comprising a central hole as well as at least one additional hole and/or inclined tray section.
4.- Bioreactor according to item 2 or 3, further comprising stationary additional radial arms attached to said vertical cylindrical vessel.
5.- Bioreactor according to item 1, wherein said radial arms are attached to said vertical cylindrical reaction vessel and said rotation means are means for rotating said vertical cylindrical reaction vessel.
6.- Bioreactor according to item 5, further comprising horizontal trays fixed to said vertical central tube, each tray comprising a central hole as well as at least one additional hole and/or inclined tray section. 7.- Bioreactor according to item 5 or 6, further comprising stationary additional radial arms attached to said vertical central tube.
8.- Bioreactor according to item 3 or 6, wherein said inclined tray section is inclined downwards.
9.- Bioreactor according to item 8, wherein said inclined tray section is inclined by 1 to 90 degrees from said horizontal tray.
10.- Bioreactor according to any one of items 1 to 9, wherein said radial arms are arranged along the vertical axis of said vertical cylindrical reaction vessel next to another on planes.
11.- Bioreactor according to item 10, wherein the width of said radial arms is between 10 and 1000 mm.
12.- Bioreactor according to item 10 or 11, wherein the distance between the ends of two adjacent radial arms on the same plane near the internal wall of said vertical cylindrical reaction vessel is between 10 and 1000 mm.
13.- Bioreactor according to any one of items 10 to 12, wherein said planes are separated from each other by a distance of between 10 et 1000 mm.
14.- Bioreactor according to any one of items 10 to 13, wherein said arms located on different planes are aligned so as to prevent the downward translocation of solid matrix material through the bioreactor. 15.- Bioreactor according to any one of items 1 to 9, wherein said radial arms are arranged along the vertical axis of said vertical cylindrical reaction vessel so as to form a helix.
16.- Bioreactor according to any one of items 4 or 7, wherein said radial arms and optionally said stationary additional radial arms alternate with said horizontal trays along the vertical axis of said vertical cylindrical reaction vessel.
17.- Bioreactor according to any one of items 1 to 16, further comprising an air inlet.
18.- Bioreactor according to any one of items 1 to 17, further comprising an exhaust gas outlet.
19.- Bioreactor according to any one of items 1 to 18 wherein monitoring devices, actuators, gas removal and gas and liquid feed lines are provided in or below said radial arms and/or optionally said stationary radial arms.
20.- Bioreactor according to any one of items 1 to 19 wherein a tubing to carry inlet gas and/or a tubing to exit gas and/or a tubing to carry growth media and water are/is placed on a pathway through said central tube and said radial arms and/or optionally said stationary radial arms.
21.- Bioreactor according to any one of items 4 or 7 , where the horizontal trays and/or radial arms are spaced by approximately 10 to 500 mm along the vertical axis of said vertical cylindrical reaction vessel. 22.- Bioreactor according to any one of items 1 to 21, wherein regions comprising a certain number of probes and actuators are defined within the bioreactor.
23.- Method for the continuous production of micro organisms and products of micro organisms by solid phase fermentation, wherein a bioreactor according to any one of items 1 of 22 is used, the flow of the solid matrix material comprising substrate and active solid phase culture being from the top to the bottom of the vertical cylindrical reaction vessel.
24.- Method according to item 23, wherein the rate of downward movement of solid matrix material is controlled uniquely by the radial arms and optionally the stationary additional radial arms and/or trays .
25.- Use of a bioreactor according to any one of items 1 of 22 for the continuous production of micro-organisms and products of micro-organisms by solid state fermentation.
26.- Use of a bioreactor according to any one of items 1 to 22 to produce a fermentation product which is an enzyme catalyst, wherein said enzyme catalyst is fed directly to a hydrolysis reactor.
27.- Use of a bioreactor according to any one of items 1 to 22 to produce a fermentation product which is an enzyme catalyst or micro organism, wherein said enzyme catalyst or micro organism is fed directly to a reactor for the treatment of wastes . 28.- Use of a bioreactor according to any one of items 1 to 22 to produce a fermentation product which is a catalyst, wherein said catalyst is fed directly to a reactor for the whitening of paper pulp.
The above items can be combined in any other technically possible way.
Other aspects and advantages of the invention will become apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood from the following description thereof given by way of example only, in which:
Fig. 1 is a profile view showing a bioreactor according to the invention;
Fig. 2 is a profile view of the bioreactor of the invention, wherein the outer bioreactor shell is removed;
Fig. 3a is top plan view of a representative tray and arms;
Fig. 3b is a top plan view of preferred tray;
Fig. 3c is a side cross-sectional view of the tray of Fig. 3b;
Figure 4 is a perspective view of arms attached to the central tube ; and Figure 5 is a front view of arms attached to central tube and positioned to form a helix.
DETAILED DESCRIPTION OF THE INVENTION
Referring to Fig. 1, a bioreactor in accordance with the principles of the invention will now be described.
The bioreactor comprises a fermentation vessel 1, growth media tanks 2, solid matrix feed hopper 3 and inlet air filter 4.
The fermentation vessel is comprised of an outer shell wall in the form of a cylinder. The ends of the cylinder are capped. Openings in the caps are provided for the continuous introduction of solid substrate at the top of the vessel and continuous withdrawal of the fermentation products from the bottom of the vessel.
In one embodiment, the bioreactor of the invention does not comprise horizontal trays. The bioreactor of the invention then preferably comprises horizontal arms having the form of a cylinder or a plane.
In another embodiment of the invention, the bioreactor comprises horizontal trays.
In Fig. 2, the outer bioreactor shell was removed, showing the horizontal trays 5 and arms 6, central tube 7, air/exhaust gas tube 10, raw material inlet 8 and product recovery outlet 9. Mechanical agitation means including a motor are provided in the housing 15. 0
The horizontal trays 5 are in form of disks having the same diameter as the inner diameter of the fermentation vessel 1 and are fixed to the inside of the vessel such that the surface of each tray is perpendicular or nearly perpendicular to the longitudinal vertical axis of the vessel. The series of trays are positioned, their faces on parallel planes, from one end to the other end of the vessel and the spacing between the trays is between 1 and 500 mm.
As can be seen in Fig. 3a, each tray 5 contains slits or through holes 14 that are not located in the centre of the tray 5.
Referring to Figs. 3b and 3c, each tray 5 is preferably cut along radial lines extending from the circumference of the tray 5 to a point near the central hole 11 of the tray 5 to form one or several tray sections 14a. The tray sections 14a formed by cutting along the radial lines are inclined. The inclination is preferably approximately 5 degrees downward from the plane of the tray.
Each tray 5 contains one hole 11 located in the centre of the tray.
Referring to Figs. 4 and 5, central tube 7 has approximately the same length as the fermentation vessel 1 and a much smaller diameter and is positioned along the longitudinal axis of the fermentation vessel 1 in the holes 11 located in the centre of the trays 5. The arms 6 approximately have the same length as the radius of the circular trays less the radius of the central tube 7 and are attached to the central tube 7 such that movement of the arms 6 relative to the trays 7 provides effective translocation of the fermented material across the surface of the tray 5. Additional holes 14 are provided in the tray for the passage of the solid material. In addition at least one stationary arm is preferably located between each pair of circular trays 5 and the arms 6 are positioned so as to maximize the agitation of the matrix material, the efficient use of the volume of the fermentation vessel 1 as well as the transfer of the matrix material through the fermentation vessel 1 in the manner of plug flow.
Preferably, the radial arms 6 or stationary additional arms have a scraper that contacts the tray. The relative movement of the scraper to the tray then displaces the matter on the tray. Each radial arm 6 and/or stationary additional arm may then be paired with one tray.
The width of each arm is between 20 and 1000 mm. The length of each arm is equal to the distance from the vessel outer wall to the central shaft less between 2 and 50 mm. The height of the arms is between 10 and 500 mm. The above mentioned arms and trays of both embodiments may be used in any combination in order to optimise mass transfer and agitation of the solid matrix material.
Operation of the bioreactor Continuous flow of solid matrix material is due to the force of gravity and the action of moving arms or trays on the solid matrix material. Flow of the solid matrix material in the downward direction is between arms, through additional holes and/or inclined tray sections in the horizontal trays. The rate of downward flow of the solid matrix material is controlled by contact with the arms or the trays . Control of gas composition, temperature, humidity and growth media feed may be effected by the use of sensors and actuators positioned on the arms, trays and vessel wall.
Process monitoring probes may be attached at appropriate positions in the bioreactor.
Process control actuators may be attached at appropriate positions in the bioreactor.
Process monitoring and control may be coordinated by specific process logic and a controller. For the purpose of process control, the bioreactor volume may be divided into logical sectors composed of a subset of the total number of probes and actuators.
Regions comprising a certain number of probes and actuators
(for example for inlet or outlet valves) may be defined within the bioreactor for the purpose of organizing data for continuous monitoring and control of temperature, humidity, oxygen level and other parameters important for optimising productivity.
The bioreactor can be equipped with a Clean-In-Place (CIP) system.
Mechanical power to rotate the bioreactor components may be provided by electric motors or pneumatic devices.
The central bioreactor tube 7 can be rotated in a clockwise and counter-clockwise direction while the outer vessel wall is immobile.
Alternately, the vertical cylindrical reaction vessel 1 can be rotated in a clockwise and counter-clockwise direction while the central bioreactor tube 7 is immobile. When the radial arms are attached to the vertical central tube 7, the trays 5 are attached to the internal wall of the cylindrical vertical vessel, and conversely.
The stationary additional arms are attached to the immobile, part, i.e. either the central tube or to the internal wall of the vertical cylindrical reaction vessel.
Inlet air is preferably filtered to prevent entry of contaminant microbes.
A means of removing exhaust gas 10 may be provided at the top of the vessel 1.
Means for the control of solid matrix flow rate, PLC and relevant process monitoring and control devices and a clean- in-place system may also be provided.
Means for cooling and/or heating the reaction vessel may also be provided.
A means of controlling the temperature by convection or evaporative cooling may also be provided. Tubing to carry inlet gas may be placed on a pathway through the central tube and above mentioned arms .
Tubing to carry exit gas may be placed on a pathway through the central tube and above mentioned arms .
Tubing to carry growth media and water may be placed on a pathway through the central tube and above mentioned arms .
The radial arms may be provided with nozzles to spray water or inject air into the vessel.

Claims

1.- A bioreactor for the continuous production of micro- organisms and products of micro-organisms by solid state fermentation, comprising a vertical, cylindrical reaction vessel (1) having a raw material inlet (8) and a product recovery outlet (9) and containing a vertical central tube (7) extending from the top to the bottom of said vertical cylindrical reaction vessel (1); radial arms attached to said vertical central tube
(7) or to said vertical cylindrical reaction vessel ( 1) ; and - rotation means to rotate said vertical central tube (7) or said vertical cylindrical reaction vessel around the vertical axis of said vertical cylindrical reaction vessel (1).
2.- Bioreactor according to claim 1, wherein said radial arms are attached to said vertical central tube (7) and said rotation means are means for rotating said vertical central tube (7) .
3.- Bioreactor according to claim 2, further comprising horizontal trays (5) fixed to the inside of said vertical reaction vessel (1), each tray comprising a central hole (11) as well as at least one additional hole (14) and/or inclined tray section (14a) .
4.- Bioreactor according to claim 2 or 3, further comprising stationary additional radial arms attached to said vertical cylindrical vessel (1) .
5.- Bioreactor according to claim 1, wherein said radial arms (6) are attached to said vertical cylindrical reaction vessel (1) and said rotation means are means for rotating said vertical cylindrical reaction vessel (1).
6.- Bioreactor according to claim 5, further comprising horizontal trays (5) fixed to said vertical central tube (7), each tray comprising a central hole (11) as well as at least one additional hole (14) and/or inclined tray section (14a) .
7.- Bioreactor according to claim 5 or β, further comprising stationary additional radial arms attached to said vertical central tube (7) .
8.- Bioreactor according to claim 3 or 6, wherein said inclined tray section (14a) is inclined downwards.
9.- Bioreactor according to claim 8, wherein said inclined tray section (14a) is inclined by 1 to 90 degrees from said horizontal tray (5) .
10.- Bioreactor according to any one of claims 1 to 9, wherein said radial arms (6) are arranged along the vertical axis of said vertical cylindrical reaction vessel (1) next to another on planes .
11.- Bioreactor according to claim 10, wherein the width of said radial arms (6) is between 10 and 1000 mm.
12.- Bioreactor according to claim 10 or 11, wherein the distance between the ends of two adjacent radial arms (6) on the same plane near the internal wall of said vertical cylindrical reaction vessel (1) is between 10 and 1000 ram.
13.- Bioreactor according to any one of claims 10 to 12, wherein said planes are separated from each other by a distance of between 10 et 1000 mm.
14.- Bioreactor according to any one of claims 10 to 13, wherein said radial arms (6) located on different planes are aligned so as to prevent the downward translocation of solid matrix material through the bioreactor.
15.- Bioreactor according to any one of claims 1 to 9, wherein said radial arms (6) are arranged along the vertical axis of said vertical cylindrical reaction vessel (1) so as to form a helix.
16.- Bioreactor according to any one of claims 4 or 7, wherein said radial arms (6) and optionally said stationary additional radial arms alternate with said horizontal trays
(5) along the vertical axis of said vertical cylindrical reaction vessel (1) .
17.- Bioreactor according to any one of claims 1 to 16, further comprising an air inlet.
18.- Bioreactor according to any one of claims 1 to 17, further comprising an exhaust gas outlet (10) .
19.- Bioreactor according to any one of claims 1 to 18 wherein monitoring devices, actuators, gas removal and gas and liquid feed lines are provided in or below said radial arms (6) and/or optionally said stationary radial arms.
20.- Bioreactor according to any one of claims 1 to 19 wherein a tubing to carry inlet gas and/or a tubing to exit gas and/or a tubing to carry growth media and water are/is placed on a pathway through said central tube (7) and said radial arms (6) and/or optionally said stationary radial arms .
21.- Bioreactor according to any one of claims 4 or 7, where the horizontal trays (5) and/or radial arms (6) are spaced by approximately 10 to 500 mm along the vertical axis of said vertical cylindrical reaction vessel (1).
22.- Bioreactor according to any one of claims 1 to 21, wherein regions comprising a certain number of probes and actuators are defined within the bioreactor.
23.- Method for the continuous production of micro organisms and products of micro organisms by solid phase fermentation, wherein a bioreactor according to any one of claims 1 of 22 is used, the flow of the solid matrix material comprising substrate and active solid phase culture being from the top to the bottom of the vertical cylindrical reaction vessel
(D •
24.- Method according to claim 23, wherein the rate of downward movement of solid matrix material is controlled uniquely by the radial arms (6) and optionally the stationary additional radial arms and/or trays (5) .
25.- Use of a bioreactor according to any one of claims 1 of 22 for the continuous production of micro-organisms and products of micro-organisms by solid state fermentation.
26.- Use of a bioreactor according to any one of claims 1 to 22 to produce a fermentation product which is an enzyme catalyst, wherein said enzyme catalyst is fed directly to a hydrolysis reactor.
27.- Use of a bioreactor according to any one of claims 1 to 22 to produce a fermentation product which is an enzyme catalyst or micro organism, wherein said enzyme catalyst or micro organism is fed directly to a reactor for the treatment of wastes.
28.- Use of a bioreactor according to any one of claims 1 to 22 to produce a fermentation product which is a catalyst, wherein said catalyst is fed directly to a reactor for the whitening of paper pulp.
PCT/IB2008/000397 2007-02-23 2008-02-22 Bioreactor for continuous production of micro-organisms and products of micro-organisms by solid state fermentation WO2008102249A1 (en)

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