RESUMEN
Large-scale bioprocesses are increasing globally to cater to the larger market demands for biological products. As fermenter volumes increase, the efficiency of mixing decreases, and environmental gradients become more pronounced compared to smaller scales. Consequently, the cells experience gradients in process parameters, which in turn affects the efficiency and profitability of the process. Computational fluid dynamics (CFD) simulations are being widely embraced for their ability to simulate bioprocess performance, facilitate bioprocess upscaling, downsizing, and process optimisation. Recently, CFD approaches have been integrated with dynamic Cell reaction kinetic (CRK) modelling to generate valuable information about the cellular response to fluctuating hydrodynamic parameters inside large production processes. Such coupled approaches have the potential to facilitate informed decision-making in intelligent biomanufacturing, aligning with the principles of "Industry 4.0" concerning digitalisation and automation. In this review, we discuss the benefits of utilising integrated CFD-CRK models and the different approaches to integrating CFD-based bioreactor hydrodynamic models with cellular kinetic models. We also highlight the suitability of different coupling approaches for bioprocess modelling in the purview of associated computational loads.
RESUMEN
Duckweed species (Lemnaceae) are suitable for remediation and valorization of agri-feed industry wastewaters and therefore can contribute to a more sustainable, circular economy where waste is a resource. Industrial applications will, however, require space efficient cultivation methods that are not affected by prevailing weather conditions. Here, the development and operation of a multi-tiered duckweed bioreactor is described. The developed prototype bioreactor depicted in this paper is composed of four cultivation layers (1 m2 each) with integrated LED lighting (generating up to 150 µmol m-2 s-1 ), a system of pumps and valves to manage the recirculatory flow (2.5 L min-1 ) of wastewater, and an automatic harvesting system. Using a nutrient poor medium, good growth of the duckweed species Lemna minor was achieved in the bioreactor, and this was matched by strong nutrient depletion from the medium, especially for phosphorus (45-mg total phosphorus [TP] removed per m-2 day-1 ). A fully automatic harvesting arm reliably captured similar amounts of duckweed biomass across multiple harvesting cycles, revealing a future scenario whereby labor and interventions by human operators are minimized. Further developments to advance the system towards fully automated operation will include, for example, the use of specific nutrient sensors to monitor and control medium composition. It is envisaged that multi-tiered, indoor bioreactors can be employed in the agri-feed industry where wastewaters are, in many cases, continuously generated throughout the year and need remediating immediately to avoid costly storage. Given the extensive use of automation technology in conventional wastewater treatment plants, multi-tiered duckweed bioreactors can be realistically integrated within the operating environment of such treatment plants. PRACTITIONER POINTS: Duckweed is suitable for remediation and valorization of agri-feed wastewater. Industrial duckweed applications require space efficient cultivation methods. Development and operation of a multi-tiered duckweed bioreactor is detailed. Flow dynamics and automatic harvesting in the bioreactor are optimized. It is concluded that a multi-tiered bioreactor can be used in industry.