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Design of nutrient gas-phase bioreactors: a critical comprehensive review

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Abstract

To reach an efficient and economical gas-phase bioreactor is still one of the most critical challenges in biotechnology engineering. The numerous advantages of gas-phase bioreactors (GPBs) as well as disadvantages of these bioreactors should be exactly recognized, and efforts should be made to eliminate these defects. The first step in upgrading these bioreactors is to identify their types and the results of previous research. In the present work, a summary of the studies carried out in the field of cultivation in these bioreactors, their classification, their components, their principles and relations governing elements, modeling them, and some of their inherent engineering aspects are presented. Literature review showed that inoculation of shoots, roots, adventurous roots, callus, nodal explants, anther, nodal segment, somatic embryo, hairy roots, and fungus is reported in 15, 2, 2, 2, 3, 2, 1, 1, 37, and 5 cases, respectively.

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Abbreviations

A m :

Amplitude of sound wave (m)

C :

Speed of sound (m s−1)

C C :

Cunningham slip correction factor (-)

C c :

Critical concentration of the nutrient (mL mg−1)

C E :

Concentration of the nutrient at equilibrium (mL mg−1)

C s :

Concentration of the limiting nutrient in the medium (g L−1)

D :

Sauter mean diameter (m)

d :

Disc diameter (m)

d 0 :

The initial diameter of the jet or nozzle outlet diameter (m)

D f :

Diameter of the fiber (hairy root) (m)

d m :

Mean diameter (m)

D p :

Diameter of the mist particle (m)

DW f :

Final dry weight of the hairy roots (g)

DW i :

Initial dry weight of the hairy roots (g)

f :

Frequency (H)

F 0 :

Initial feed flow rate per unit mass, felt by the bed (mL day−1 mg−1)

FW :

Fresh weight of hairy roots (g)

G L :

Mass flow rate of fluid entering the disc (kg h−1)

h :

Diameter of the holes or the height of the blades on the disc (m)

H c :

Critical specific liquid hold up (mL mg−1)

H s :

Specific liquid hold up at saturation (mL mg−1)

I :

Power surface intensity (ratio of power delivered at the surface) (kg s−3)

k :

Boltzmann constant (-)

k 1 :

Growth rate constant of primary root after branching starts (mg day−1 mg−1)

k 2 :

Growth rate constant of branches during branching period (mg day−1 mg−1)

k 3 :

Growth rate constant of branches after maturity time (mg day−1 mg−1)

k cm :

Rate of nutrient consumption by roots per unit mass of the roots (Day−1)

k d :

Proportionality constant for drainage equation (Day−1)

k f :

Biomass per unit mass of nutrient uptake (mg mg−1)

k g :

Fraction of nutrient utilized for growth (-)

k m :

Growth rate constant of primary hairy root after maturity time (mg day−1 mg−1)

k n :

Knult number (-)

k tot :

Growth rate constant of root (mg day−1 mg−1)

k u :

Kuwabara number (-)

L :

Length of the bed (m)

l :

Length of hairy root (m)

l 0 :

Initial length of hairy root (cm)

l 1 :

Length of hairy root before branching starts (cm)

l 2 :

Length of hairy root after branching and before maturity (cm)

l 3 :

Length of hairy root after maturity and before harvesting (cm)

M :

Mass of hairy root (kg)

m :

Mass fraction of the droplets with diameter Dp (kg)

ṁ a :

Mass flow rate of air (kg s−1)

m f :

Mass of fructose (g)

m g :

Mass of glucose (g)

ṁ L :

Mass flow rate of liquid (kg s−1)

m p :

Mass of a mist particle (kg)

m s :

Mass of sucrose (g)

N :

Rotational velocity of disc (rev min−1)

n :

Number of holes or blades on the disc (-)

Oh :

Ohnesorge number (-)

Q :

Volumetric flow rate (m3 s−1)

Q m :

Volumetric flow rate of mist during the mist-On cycle (m3 min−1)

R :

Radius of culture chamber (m)

r :

Radius of hairy root (m)

R aL :

Mass ratio of air to liquid (-)

t :

Film thickness at the nozzle outlet (m)

T :

Temperature (℃)

T c :

Maximum duration of the mist-On cycle (min)

T i :

Time (Day)

T M :

Maximum duration of the mist-Off cycle (min)

V :

Volume of the Cultivation Chamber (L)

V 0 :

Velocity of the droplets through the root bed (m s−1)

V dep-med :

The volume of culture medium that is absorbed during a day (m3)

v g :

Velocity of the gas (air) (m s−1)

v p :

Velocity of the mist particles (m s−1)

V req :

Required volume of the culture medium (mL)

Wn :

Weber number (-)

Wn a :

Weber number of air (-)

y 1 :

Distance the particle’s streamline (m)

Y s :

Apparent biomass yield based on sucrose (g g−1)

Z :

Height of nozzle above culture bed (m)

α :

Fraction of the bed volume filled with fiber fibers (roots) (-)

β :

Packing fraction (-)

ΔDW :

Dry weight changes (g)

ΔGE :

Glucose equivalent changes (g)

ΔP L :

Injection pressure differential across nozzle (Pa)

Δt :

Period (Day)

Δt 1 :

The period before branching starts (Day)

Δt 2 :

The period after rooting and before maturity (Day)

Δt 3 :

The period after maturity and before harvesting (Day)

η :

Overall capture efficiency (-)

η B :

Percent of droplets that remain in the bed (-)

η c :

Combined capture efficiency of all mechanisms involved (-)

η Diff :

Diffusion efficiency (-)

η i :

Efficiency for each individual mechanism (-)

η Int + Imp :

Efficiency of both interception and impaction (-)

θ :

Jet cone angle (Degree)

µ :

Fluid dynamic viscosity (kg m−1 s)

µ a :

Viscosity of the air (kg m−1 s)

µ L :

Liquid dynamic viscosity (kg m−1 s)

µ m :

Mist dynamic viscosity (kg m−1 s)

ξ :

Average specific growth rate (g day−1)

ρ :

Density of hairy root (kg m−3)

ρ a :

Density of air (kg m−3)

ρ FW :

Density of fresh weight of hairy roots (g mL−1)

ρ L :

Density of liquid (kg m−3)

σ :

Surface tension (N m−1)

ω :

The time mist generator system is on (min h−1)

B5 :

Gamborg’s medium [168] (-)

BA :

6-Benzyladenine (-)

BAP :

6-Benzylamino-purine (-)

BM :

Basal nutrient medium [72] (-)

CCCM :

Chemical composition of culture medium (-)

CFD :

Computational fluid dynamics (-)

GPB :

Gas-phase bioreactor (-)

GPBs :

Gas-phase bioreactors (-)

IAA :

Indole acetic acid (-)

IBA :

Indole-3-butyric acid (-)

ITB :

Inoculate tissue in bioreactor (-)

MS :

Murashige and Skoog’s medium [169] (-)

NAA :

α-Naphthaleneacetic acid (-)

OCN :

Off/on cycle of nourishment (mist-on: whole cycle) (-)

PNSS :

Pump-nozzle spraying system (-)

PSCB :

Plant species cultivated in bioreactor (-)

SH :

Schenk and Hildebrandt’s medium [170] (-)

SSC :

Semi-solid culture (-)

SSEPP :

Spray system equipped with a peristaltic pump (-)

SSS :

Semi-solid System (-)

TAS :

Type of atomizer system (-)

TCC :

Temperature of cultivation chamber during the growth period (℃)

TNS :

Trickling nozzle system (-)

UAN :

Ultrasonic atomizer nozzle (-)

UTEAW :

Ultrasonic transducer equipped with acoustic window (-)

UTOW :

Ultrasonic transducer with open window (-)

VCC :

Volume of the culture chamber (L)

VCM :

Volume of the culture medium (L)

WPM :

McCown’s woody plant [171] (-)

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Acknowledgements

The authors would like to thank the University of Tehran and Dr. Mohammad Hassan Torabi.

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Authors and Affiliations

  1. Department of Mechanics of Biosystem Engineering, Faculty of Engineering and Technology, College of Agriculture and Natural Resources, University of Tehran, Karaj, Alborz, Iran

    Amir Hossein Mirzabe, Ali Hajiahmad & Shahin Rafiee

  2. Department of Food Technology, College of Aburaihan, University of Tehran, Tehran, Iran

    Ali Fadavi

  3. Department of Mechanical Engineering of Biosystems, Faculty of Agricultural Engineering and Technology, University of Tehran, Karaj, Alborz, Iran

    Ali Hajiahmad

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  1. Amir Hossein Mirzabe
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Mirzabe, A.H., Hajiahmad, A., Fadavi, A. et al. Design of nutrient gas-phase bioreactors: a critical comprehensive review. Bioprocess Biosyst Eng 45, 1239–1265 (2022). https://doi.org/10.1007/s00449-022-02728-6

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