The Viability of Flocculent Yeast as a Biomass Feedback Mechanism and its Effect on Ethanol Production in a Chemostat Ivan Hong Hee Kean, Yoke Kwan Sam, Aadil Fotedar Industrial Process and Bioremediation, Murdoch University Abstract A chemostat with biomass feedback was run with Saccharomyces cerevisiae under anaerobic conditions to study the efficacy of yeast flocculation as biomass feedback mechanism and its effect on ethanol production. The reactor was kept at a constant temperature of 30°C with stirring. The concentration of glucose in the media was 100g/L, the highest concentration used thus far. A dilution rate of 0.075h-1 was used for most of the experiment; this was later increased to 0.75h-1 on the last day. The biomass concentration showed an exponential increase over time and achieved a peak of 8.064 x 1011 cells/L, a cell density more than a thousand times greater than that reported in a previous group and was achieved in a quarter of the time. The highest concentration of ethanol measured was 47.22g/L translating to a 92.39% conversion yield. Introduction Beer brewing has a long history dating back as far as ancient Egypt. For much of its history, beer was produced using a slow batch process in a single vessel. As with other industrial processes, significant improvements in productivity and efficiency can be obtained by switching from a batch to continuous process. In 1950, Morton Coutt developed a method of brewing beer through continuous fermentation. This method replaced the batch process and allowed for rapid fermentation, lower capital and labour costs, reduction in batch to batch variation and allowed for process automation. To achieve such rapid fermentation, a biomass feedback mechanism is required. The only method used in industrial scale brewing is through the process of yeast flocculation. Yeast flocculation is an asexual, reversible and calcium-dependent process where cells adhere to form flocs of thousands of cells (Bony et al. 1997; Stratford 1989). These flocs either rise to the surface or sediment depending on the type of yeast used and can be easily separated from green beer at the end of fermentation. In the process patented by Coutts, a cascading series of vessels are used with the last vessel in the series left unstirred to allow for the separation of yeast from the beer. This yeast is then piped back into the first vessel where it mixes with the incoming wort (Campbell, Sarah L.). The incoming wort is oxygenated to stimulate growth and reproduction, but not to the extent that it would encourage the growth of aerobic microbial contaminants that may be present. Oxygen is essential for the synthesis of sterols and fatty acids necessary for cell wall production in yeast. Yeast perform ethanol fermentation in the absence of oxygen, where sugars such as glucose, fructose, sucrose, maltose and maltotriose are converted to carbon dioxide, ethanol and ATP through the Embden-Myerhof-Parnas pathway also known as the glycolytic pathway (figure 1). The stoichiometry for this process is represented as: C6H12O6 + 2ADP + 2Pi → 2C2H5OH + 2CO2 + 2ATP + 2H2O The aim of this experiment was to determine the efficacy of flocculent yeast as a mechanism for biomass feedback and its effect on ethanol production with high dilution rates in a chemostat. The strain of yeast used in this experiment was selected based on its fast fermentation and high sedimentation characteristics. Materials and Method Materials: A. Apparatus: 1. 2 x 1L Schott vessels for feed and reactor. 2. 1x 4L Schott vessel for harvest. 3. Approximately 3m of silicon tubing. 4. 1x 1mL syringe with 18G syringe needle for the feed inflow to the reactor 5. 2x fermentation lock 6. 1x air filter 7. 1x IEC magnetic stirrer and stirring rod 8. 2x aquarium heater 9. 1x steel pot for water bath 10. 3x timers 11. 1x head clamp 12. 3 retort stand with 4 retort clamps 13. 1x Chemaster dual pump 14. 1x Cole Palmer console drive one way pump 15. 1x Cole Palmer Masterflex L/S Economy drive one way pump 16. 1x thermometer 17. 1x separation funnel 18. 2x measuring cylinder with 2x beaker for CO2 measurement 19. 1x air regulator 20. 4x rubber bungs 21. Connectors B. Media Component g/L D-glucose 100 Yeast extract 8.5 NH4Cl 1.1 MgSO4.H2O 0.11 CaCl2.H2O 0.87 Distilled Water 1L Table 1: Media component adapted from the previous group of Gibbs and Humphris. Method Inoculum and media 0.5g of Safale S-04 dry ale yeast from the Malthouse Homebrew Supplies was used for preparation of the batch culture. The inoculum was left for 48 hours in a 30°C water bath. The media was prepared according to table 1. 100g/L of glucose was used in preparation of the batch and chemostat media in the final runs; this is considerably higher than in previous reports which used glucose concentrations ranging between 20g/L to 75g/L. An initial glucose concentration of 20g/L was used but was found to be insufficient for good yeast growth and the concentration was increased to 100g/L. A spare batch culture was left in the 30°C water bath for use if the chemostat encountered problems such as contamination. Pumps Three pumps with different flow rate were connected to three timers that were calibrated to obtain the desired flow rates. For calibration water was pumped to a measuring cylinder over a minute and the amount of water pumped measured. The settings chosen for these pumps should be discrete (i.e. 1 or 2 and not 2.3) so as to prevent error. The settings should not be too low as there may be problems with inertia when used in conjunction with timers, if the setting is to low, the volume pumped will be lower than what was measured. The diameter and rigidity of the tubing used varied depending on the pump. The flow rate for the 2 way pump was set to 37.5ml/h (D=0.075 h-1), the flow rate from the reactor into the separating funnel was set to 50 ml/h (D=0.1 h-1) and the flow rate from the separating funnel back into the reactor was set to 12.5 ml/h (D=0.025 h-1). This setting allowed for a constant volume to be maintained throughout the system. The flow rate for the pumps used are as follows: Chemaster pump: 660 ml/h Cole Palmer console drive one way pump: 870 ml/h Cole Palmer Masterflex L/S Economy drive one way pump: 5795 ml/h Based on these rates, it was calculated that the Chemaster pump had to be switched off for 16.6 seconds for every second it was switched on to achieve the desired flow rate of 37.5 ml/h. The Cole Palmer console drive one way pump had to be switched off for 68.6 seconds for every second it was switched on to achieve the flow rate of 12.5 ml/h and the Cole Palmer Masterflex L/S Economy drive one way pump had to be switched off for 115.9 seconds for every second it was on to achieve the flow rate of 50ml/h. Tubing Silicon based tubing was used so it could be autoclaved. Feed Vessel Air from an outlet was passed through a regulator to allow for control of air flow, then passed through a filter to prevent contamination. This allowed the feed to be oxygenated to saturation to encourage yeast growth. The media vessel was placed on ice to prevent growth of contaminants. Reactor vessel The batch culture was removed from the 30 °c water bath and connected to the chemostat. A rubber bung was used to ensure it was air-tight. Oxygenated medium was pumped into the reactor through a dripper system based on previous report by Chiu et al. (2007). A length of tubing was placed halfway to the bottom of the reactor vessel for outflow into the yeast separator. The reason for this was that even if the flow rate from the reactor to the yeast separator was too high the reactor volume would not go below 500ml. Another length of tubing connected the bottom of the yeast separator to the reactor; this was the inflow of yeast cells back into the reactor. A fourth length of tubing connected the reactor to a carbon dioxide trap. The temperature of the reactor vessel was kept at 30 °C throughout the experiment. Yeast separator A separating funnel was used as the yeast separator. The yeast would flocculate and sediment to the bottom of the funnel allowing it to be pumped back into the reactor. The yeast separator also had a CO2 measuring system attached to it monitor any fermentation that may occur in the yeast separator. CO2 measurements Two CO2 measuring devices were made, one attached to the reactor vessel and one to the yeast separator. A 1L measuring flask was stood upside down in a 5L beaker approximately half full of water. All air was removed from the flask using a tube and a syringe and a tube leading from the two vessels led into the measuring flasks. As CO2 would escape into the flask it would push the water level down and the amount of gas could be measured. Harvest vessel The harvest vessel was placed in ice to prevent additional fermentation that may take place. A fermentation lock was fitted to the lid of the harvest vessel as well as the substrate vessel to prevent pressure build-up. Sampling Samples was taken daily and the pH and optical density was measured. A minimum of 1ml was frozen so that the ethanol concentration could be measured later. pH Samples from the reactor, yeast separator and harvest vessels were tested using a pH meter immediately after collection. Biomass Biomass content of the reactor, yeast separator and harvest vessels were measured by a UVVis spectrophotometer at 660nm to get the optical density (OD). The OD obtained was read off on a known biomass concentration standard curve. When OD reading is higher than 1.7 a dilution was performed until the O.D. was less than 1.7. The values for the standard curve with the known biomass concentration was obtained from (Anberg el at, 2005). Ethanol Ethanol concentration was measured using a gas chromatograph (GC). Samples were frozen and handed to Ralf for GC analysis. A range of data was given back to us with the peak count of each individual sample, this was later converted to g/L of ethanol. Results Time (h) Reactor Harvest Yeast Separator 0 8.4 Not measured Not measured 19 12.14 8 Not measured D=0.075h 91 80.64 0.798 8.13 Biomass concentration Time (h) Reactor Harvest Yeast Separator 0 18.42 0 0 21 7.5 1.172 7.08 45 18.1 5.132 17.08 70 63.2 10.7 13.53 Time (h) Reactor Harvest Yeast Separator 0 63.2 0 13.53 1 26.12 21.63 25.2 Biomass concentration (1010 cells/L) Date: 9/10/2009 First Chemostat Run -1 (1010 cells/L) Date: 12/10/2009 Second Chemostat Run D=0.075h-1 Biomass concentration (1010 cells/L) Date: 15/10/2009 Third Chemostat Run D=0.75h-1 Table 2. Biomass concentration for the reactor, harvest vessel and yeast separator during each of the three runs This table shows the biomass concentration over time for each of the three runs. The biomass concentration can be seen increasing in the reactor for the first two runs. However the biomass is seen to be decreasing in the reactor in the third run and seen to be increasing in both the yeast separator and harvest vessel. Highest biomass concentrations for each run are in bold. All the parameters for the second run are graphed Ethanol concentration Time (h) Reactor Harvest Yeast Separator (g/L) 0 Not measured 0 Not measured Date: 9/10/2009 19 53.3385 33.3045 Not measured First Chemostat Run 91 20.817 28.107 Not measured Ethanol concentration Time (h) Reactor Harvest Yeast Separator (g/L) 0 33.9255 29.9565 32.5755 Date: 12/10/2009 21 13.095 23.76 17.631 Second Chemostat Run 45 28.998 32.94 47.223 D=0.075h-1 70 40.2435 26.649 13.743 Ethanol concentration Time (h) Reactor Harvest Yeast Separator (g/L) 0 40.2435 0 13.743 Date: 15/10/2009 1 25.731 37.5705 33.6285 D=0.075h-1 Third Chemostat Run D=0.75h-1 Table 3. Different Ethanol concentration for the reactor, harvest vessel and yeast separator during each of the three runs. This table shows the ethanol concentration over time for each of the three runs. The ethanol concentration can be seen increasing in the reactor for the second run. In the third run, the ethanol concentration is observed to be increasing as it moves from the reactor to the yeast separator to the harvest vessel. Highest ethanol concentrations for each run are in bold. pH reading Yeast Separator Time (h) Reactor Harvest 0 3.37 19 3.25 3.75 91 2.17 3.51 Time (h) Reactor Harvest Yeast Separator 21 5.02 3.67 5.09 45 2.65 3.05 2.57 70 2.87 2.91 2.89 Time (h) Reactor Harvest Yeast Separator 0 2.87 1 3.27 Date: 9/10/2009 First Chemostat Run D=0.075h-1 pH reading Date: 12/10/2009 Second Chemostat Run D=0.075h-1 pH reading 0 Date: 15/10/2009 Third Chemostat Run D=0.75h-1 2.89 2.75 3.39 Table 4: pH Reading recorded for the reactor, harvest vessel and yeast separator during each of the three runs. The pH can be seen decreasing in the second run from approximately 5 to approximately 2.6 for the reactor and yeast separators. pH is observed to have reached a steady state in the second run after 45 hours. CO2(ml/ h) Expected CO2 CO2/expecte (ml/h) d CO2(%) Expected Ethanol Ethanol Ethanol concentration concentration concentration /Expected in reactor Ethanol (g/L) (g/L) concentration D=0.075h-1 775 1021 75.91 53.3385 51.11 104.36 D=0.75h-1 800 10210 7.84 25.731 51.11 50.34 Table 5. Carbon Dioxide and Ethanol Concentration for different dilution rates. The volume of carbon dioxide produced was measured twice, once for each flow rate. The actual over expected values do not match. Graph 1. Ethanol Concentration over time in second chemostat run D=0.075h-1 The ethanol concentration in the reactor shows a dip as it’s changed from a batch culture to a chemostat. The ethanol concentration gradually rises over time. Note that the values for all the harvest vessels represent an accumulation over time as the harvest vessel was not replaced until the end of each run. Graph 2. Biomass Concentration over time in second chemostat run D=0.075h-1 This graph also shows the same dip in biomass concentration as it is switched from a batch culture to chemostat Graph 3. pH over time in second chemostat run D=0.075h-1 pH gradually falls over time as the yeast produce acids and carbon dioxide Graph 4. Biomass Concentration, pH and Ethanol Concentration in the reactor over Time in the second chemostat run. The pH, biomass concentration and ethanol concentration in the reactor are seen to correlate closely with each other in the second run. Discussion Initial data (ethanol concentration and CO2 produced; data not included) gathered before inclusion of the biomass feedback suggested that fermentation was substrate limited. The glucose concentration of the media was then increased from 20g/L to 100g/L for the final three runs. pH pH is expected to fall during fermentation due to the release of organic acids and carbon dioxide by yeasts. The optimum pH range for yeast maintenance during fermentation is between 4-6, however as intracellular pH is relatively independent of pH in the media, it’s effect is not thought to be significant compared with other factors such as sugar concentration and temperature(Cantarelli and Lanzarini, 1989). The pH of the reactor at the end of the first run was very acidic at 2.17; this was most likely due to acid production by contaminating bacteria found growing in the feed vessel over the weekend. This was verified by viewing a sample under the microscope. However no bacteria were found to be growing in the reactor, this inhibition was most likely due to the production of acids and ethanol by the yeast. Excluding the low pH values on the last day of the first run the other measurements for the first run were stable and suggest good growth. The readings for the second run show an increase in acidity from pH 5.02 in the reactor to pH 2.65 a day later, this effect was also seen in the yeast separator. This is most probably because the yeast cells in the reactor were still actively growing and fermenting when the chemostat was initiated in the first run whereas in the second run, it was still in the lag phase. The yeast placed into the reactor for the first run were from a chemostat run just two days earlier, whereas the yeast for the second run were taken from a batch reactor that had been running for 2 weeks and had since stopped growing and fermenting as evidenced by the lack of froth and CO2 that would normally be seen in active cultures. The pH reached a steady state after two days. There was an increase in pH in the reactor and yeast separator for the third run. This is most likely caused by the high flow rate diluting the acid in the reactor and yeast separator. Carbon Dioxide CO2 readings were taken twice during the course of the experiment; one at D=0.075h-1 and the other at D=0.75h-1. The expected CO2 readings, assuming 100% conversion of glucose for these two dilution rates, are 1.021 L/h and 10.21 L/h respectively. The observed readings are lower than the expected values. The actual CO2 measured at D=0.075h-1 was 775ml/h this translates to 75.91% of the substrate being utilised and the actual CO2 measured at D=0.75h-1 was 800ml/h, which translates to a 7.83% substrate utilisation. However, these values do not correlate with the ethanol concentration measurements taken from samples on the same day. Observed ethanol concentration over actual ethanol concentration for D=0.75h-1 was approximately 50%, this is much higher than the 7.83% for CO2. This is most likely due to the difficulty of accurately collecting a large volume of CO2 within our chemostat. A large amount of froth was seen in the reactor and it is more than likely CO2 was trapped within the foam. Although the CO2 trap for the reactor was working, the CO2 trap for the yeast separator was not functioning, CO2 could have escaped from there. Carbon dioxide was also seen bubbling from the reactor to the tubing connected to it (outflow to yeast separator, inflow from yeast separator) as well as in the tubing themselves. Cell Density The optical density measurements of yeast cells in the reactor show exponential growth in the first and second runs proving that biomass feedback through the recycling of flocculent yeast is highly effective. The decline in cell density in the reactor and higher cell densities in the yeast separator and harvest vessel in the third run indicate that the yeast cells were being flushed out. The higher dilution rate resulted in increased agitation of the media and yeast within the yeast separator and less time being available for the yeast to flocculate and sediment resulting in more of them being pumped into the harvest vessel. Whether the higher dilution rate would have resulted in washout is not known as the final run was only carried out over an hour due to time and practical constraints. Ethanol The ethanol production in the first run reached a peak of 53.34g/L, 19 hours after the chemostat was started and is slightly higher than the expected amount of 51.11g/L. The cause of this could be other sources of sugar within the medium (i.e. yeast extract) but is most likely to be due to inaccuracy in measurement by the gas chromatograph. The ethanol production dropped significantly towards the end of the run, this coincides with the discovery of bacterial contamination in the feed. The decrease in ethanol production can be explained by glucose metabolism by the bacteria in the feed resulting in less glucose being available for fermentation and lowering of the pH by the production of acid by the contaminant. The ethanol concentration in the reactor for the second run drops from 33.93g/L when the yeast cells were in batch culture to 13.10g/L when they were suddenly switched to a chemostat. The ethanol concentration gradually rises to 40.24g/L at the end of the run and the ethanol concentration in the reactor correlates with the cell density of the yeast culture. The maximum amount of ethanol produced in the second run was 47.22 g/L, 92.39% of the expected amount of ethanol. This compares favourably to the results in literature; Xu et al had a conversion yield of 91.1%. A accurate comparison cannot be made with the previous year's report (Chiu et al. 2007) because the reported yield was 137% of expected, this reason for this was not mentioned. The ethanol yield for the final run was lower and the ethanol concentration can be seen increasing from 25.73g/L in the reactor to 33.63g/L in the yeast separator to 37.57g/L in the harvest vessel. This indicates that the hydraulic retention time (HRT) in the reactor was too short to allow for complete fermentation and resulted in fermentation being carried out in the other vessels. The cell density also increased two-fold in the yeast separator and harvest vessel compared with the second run. The cell density and ethanol results suggest that the dilution rate of D=0.75 h-1 (this translates to a HRT of just 80 minutes) may be too high,. Biomass Feedback Due to the inclusion of biomass feedback, the cell density increased at an exponential rate and reached cell densities that would not be possible in a standard chemostat such as those set up in previous years (Chiu et al. 2007; Bowman et al. 2002). The peak cell density was more than a thousand times greater than that reported by Bowman et al and the time taken was nearly a quarter of that. However, the current set-up would most likely result in much more yeast being accumulated in the reactor than necessary had the first and second runs been extended further. This may lead to other problems as the increased viscosity would make mixing more difficult, the cells at the bottom of the reactor, in the tubing and yeast separator may also start senescing due to the lack of nutrients and lead to other problems. In the reactor design used by Dominion Breweries, surplus yeast in the yeast separator is washed to recover as much beer as possible and then sold. Conclusions Biomass feedback through yeast flocculation is an effective method of increasing biomass in the reactor. This increase in biomass has a positive correlation with the increased concentration of ethanol. The Dm of this chemostat probably lies somewhere between 0.075h-1 and 0.75h-1. Very nice report. A lot of work went into it to get it right. Your group worked very independent and succeeded to run a sophisticated bioreactor system. Understanding is good. Writing is clear The discussion is too long and gets lost too much into describing details then addressing the aim, which is exploring to what extent continous ethanol production at dilution rates can be accomplished by using biomass feedback 8.5/10 References Amberg, David C., Daniel J. Burke, and Jeffrey N. Strathern, 2005. Methods in Yeast Genetics. A Cold Spring Harbour Laboratory Course Manual, Cold Spring Harbor Laboratory Press Bony, M. Thines-Sempoux D, Barre P, Blondin B, 1997. Localisation and cell surface anchoring of the Saccharomyces cerevisiae flocculation protein Flo1p. J Bacteriol 179:4929– 4936 Bowman, Kate, Sarah Voskuilen, Amanda Hewson, Justina Tong, 2005. Anaerobic Production of Ethanol from Commercially Prepared Apple Juice Campbell, Sarah J. The Continuous Brewing of Beer, DB Breweries Ltd. Chiu, Edwin, Gemma Fitzpatrick, Philipp Guthrod, Julius Kuah, Bastian Piltz, and Ewe Xjin Lim, 2007. The Effect of Different Dilution Rates on the Production of Ethanol in a Chemostat Gibbs, B., Humphris,S., and Krishnamurthy, P, 1998. Affect of Medium Flow Rate on EtOH Production in a Continuous Stirred Tank Bioreactor. Stratford M., 1989. Yeast flocculation: calcium specificity. Yeast 5:487–496 Xu, T. J., Zhao, X. Q., Bai, F. W. 2005. Continuous ethanol production using selfflocculating yeast in a cascade of fermentors. Enzyme and Microbial Technology 37:634-640 Recommendations Batch culture and media When yeast is obtained grow it in a batch culture which is placed at 30°C for optimal growth. Use the same ingredients as used in the media aforementioned in this report (previous reports used only 20g/L of D-glucose but this was found to be limiting in our experiment so 100g/L was used) and make sure it has been autoclaved before inoculating yeast to prevent contamination. The yeast should grow quickly and be ready for use within 48 hours. The media should be created using the same ingredients as the batch culture. Airtight It is essential that all parts of the chemostat are sealed and airtight. Make sure the tubes fit tightly into the rubber stopper lids for the bottles and the tube connectors as this is where leakage is most likely to occur. This will prevent leakage of CO2 so it can be measured as well as preventing contamination and air getting into the tubing which reduces flow capacity. Autoclaving Autoclaving the substrate reservoir containing the media, as well the other bottles used and the tubing before inserting the yeast will prevent contamination from unwanted bacteria. This is very important as it is very easy for the media to become contaminated. Make sure you use silicon pipes as they are the only ones that can be autoclaved. Substrate reservoir and harvest in ice Placing the substrate reservoir and harvest bottles in ice will also help prevent contamination. Aeration of media The media can be aerated using an oxygen pump and filter to help the biomass to cultivate. Aerating the fermenter bottle itself will mean the yeast utilize oxygen and grow aerobically so they will not produce ethanol but pumping a low amount of oxygen into the substrate reservoir container will help the yeast biomass to initially cultivate aerobically giving a larger amount biomass to anaerobically produce ethanol therefore increasing productivity. Tubing The tubing between vessels should be silicon based and as short as possible. This limits retention time of liquids and biomass in the tubing affecting flow and dilution rates. Also it is a good idea to use tubing’s that have a narrow internal diameter. Pressure release A fermentation lock should be attached to the stoppers on feed and harvest vessels to prevent build-up of pressure. This is very important as a competing experiment was destroyed this year due to a leakage because of pressure build-up. Appendix Initial Dilution rate= 0.075L Flow rate=D*V Flow rate = 0.075*0.5L Initial Flow Rate = 0.0375L/h Secondary Dilution Rate=0.75L Flow rate=D*V Flow rate=0.75*0.5L Second Flow Rate=0.375 Theoretical amount of CO2 gas and ethanol that should be produced C6H12O6 → 2C2H5OH + 2CO2 g/h of glucose in reactor= initial flow rate*g/L of glucose in media =0.0375L/h*100g/L =3.75g/h Moles of glucose= 3.75/180 =0.021moles/h Moles per hour expected of CO2 =0.021moles/h*2 =0.042 moles/h of CO2 expected L/h of CO2 expected (1 mole of gas=24.5L) =0.042moles/h*24.5L =1.021L per hour of CO2 expected when using initial flow rate g/h of glucose in reactor= secondary flow rate*g/L of glucose in media =0.375L/h*100g/L =37.5g/h Moles of glucose= 37.5/180 =0.21moles/h Moles per hour expected of CO2 =0.21moles/h*2 =0.42 moles/h of CO2 expected L/h of CO2 expected (1 mole of gas=24.5L) =0.42moles/h*24.5L =10.29L per hour of CO2 expected when using second flow rate Amount of glucose in reactor=100g/L Moles of glucose per litre present=100g/180g =0.556moles/L in reactor Moles of ethanol expected per litre = 0.556moles/L*2 =1.11moles/L of ethanol expected g/L of ethanol expected = 1.112*46 =51.11g/L of ethanol is expected to be produced