Process Engineering of the Acetone-Ethanol-Butanol (ABE) Fermentation in a Linear and Feedback Loop Cascade of Continuous Stirred Tank Reactors: Experiments, Modeling and Optimization

The production of butanol, acetone and ethanol by Clostridium acetobutylicum is a biphasic fermentation process. In the first phase the carbohydrate substrate is metabolized to acetic and butyric acid, in the following second phase the product spectrum is shifted towards the economically interesting solvents. Here we present a cascade of six continuous stirred tank reactors (CCSTR), which allows performing the time dependent metabolic phases of an acetone-butanol-ethanol (ABE) batch fermentation in a spatial domain. Experimental data of steady states under four operating conditions—with variations of the pH in the first bioreactor between 4.3 and 5.6 as well as the total dilution rate between 0.042 h−1 and 0.092 h−1—were used to optimize and validate a corresponding mathematical model. Beyond a residence time distribution representation and substrate, biomass and product kinetics this model also includes the differentiation of cells between the metabolic states. Model simulations predict a final product concentration of 8.2 g butanol L−1 and a productivity of 0.75 g butanol L−1 h−1 in the CCSTR operated at pHbr1 of 4.3 and D = 0.092 h−1, while 31% of the cells are differentiated to the solventogenic state. Aiming at an enrichment of solvent-producing cells, a feedback loop was introduced into the cascade, sending cells from a later state of the process (bioreactor 4) back to an early stage of the process (bioreactor 2). In agreement with the experimental observations, the model accurately predicted an increase in butanol formation rate in bioreactor stages 2 and 3, resulting in an overall butanol productivity of 0.76 g L−1 h−1 for the feedback loop cascade. The here presented CCSTR and the validated model will serve to investigate further ABE fermentation strategies for a controlled metabolic switch.

Process Engineering of the Acetone-Ethanol-Butanol (ABE) Fermentation in a Linear and Feedback Loop Cascade of Continuous Stirred Tank Reactors: Experiments, Modeling and Optimization

The production of butanol, acetone and ethanol by Clostridium acetobutylicum is a biphasic fer-mentation process. In the first phase the carbohydrate substrate is metabolized to acetic and bu-tyric acid, in the following second phase the product spectrum is shifted towards the economi-cally interesting solvents. Here we present a cascade of six continuous stirred tank reactors (CCSTR), which allows performing the time dependent metabolic phases of an ace-tone-butanol-ethanol (ABE) batch fermentation in a spatial domain. Experimental data of steady states under four operating conditions - with variations of the pH in the first bioreactor between 4.3 and 5.6 as well as the total dilution rate between 0.042 1/h and 0.092 1/h - were used to optimize and validate a corresponding mathematical model. Beyond a residence time distribution representation and substrate, biomass and product kinetics this model also includes the differen-tiation of cells between the metabolic states. Model simulations predict a final butanol product concentration of 8.2 g/L and a butanol productivity of 0.75 g/(L h) in the CCSTR operated at a pH in bioreactor 1 of 4.3 and D = 0.092 1/h, while 31 % of the cells are differentiated to the solventogenic state. Aiming at an enrichment of solvent-producing cells, a feedback loop was introduced into the cascade - sending cells from a later state of the process (bioreactor 4) back to an early stage of the process (bioreactor 2). In agreement with the experimental observations, the model accurately predicted an increase of butanol formation rate in bioreactor stages 2 and 3, resulting in an overall butanol productivity of 0.76 g/(L h) for the feedback loop cascade. The here presented CCSTR and the validated model will serve to investigate further ABE fermentation strategies for a controlled metabolic switch.

Study on the Nonlinear Dynamics of the Continuous Stirred Tank Reactors

Chemical processes often exhibit nonlinear dynamics and tend to generate complex state trajectories, which present challenging operational problems due to complexities such as output multiplicity, oscillation, and even chaos. For this reason, a complete knowledge of the static and dynamic nature of these behaviors is required to understand, to operate, to control, and to optimize continuous stirred tank reactors (CSTRs). Through nonlinear analysis, the possibility of output multiplicity, self-sustained oscillation, and torus dynamics are studied in this paper. Specifically, output multiplicity is investigated in a case-by-case basis, and related operation and control strategies are discussed. Bifurcation analysis to identify different dynamic behaviors of a CSTR is also implemented, where operational parameters are identified to obtain self-oscillatory dynamics and possible unsteady-state operation strategy through designing the CSTR as self-sustained periodic. Finally, a discussion on codimension-1 bifurcations of limits cycles is also provided for the exploration of periodic forcing on self-oscillators. Through this synergistic study on the CSTRs, possible output multiplicity, oscillatory, and chaotic dynamics facilitates the implementation of novel operation/control strategies for the process industry.