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Processes
Special Issues
Bioreactor Design and Optimization Process
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Bioreactor Design and Optimization Process

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Biological Processes and Systems".

Deadline for manuscript submissions: 15 December 2025 | Viewed by 4503

Special Issue Editors

Dr. Serena Lima

E-Mail Website
Guest Editor
Department of Engineering, Università degli Studi di Palermo, 90128 Palermo, Italy
Interests: microalgae; carotenoids; microalgal applications; photobioreactors; extraction techniques
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Francesca Scargiali

E-Mail Website
Guest Editor
Department of Engineering, Università degli Studi di Palermo, 90128 Palermo, Italy
Interests: Multi-phase systems; CFD; bioreactors design and modelling, microalgae exploitation; photobioreactors
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The role of biotechnology in process engineering has attracted significant interest within the scientific community due to its numerous applications. Bioreactors represent the heart of bioprocessing, being the place in which the main reactions occur. This makes bioreactor design and optimization of increasing interest for enhancing process efficiencies. In many bioprocesses, bioreactor characteristics influence a process’ economic feasibility. Consequently, developing innovative solutions for reactor design is a pressing need in bioprocess engineering.

This Special Issue requests high-quality studies focusing on topics such as the following:

  • Innovative bioreactor design;
  • CFD modeling of bioreactors;
  • Process intensification in bioreactors;
  • Mass-transfer optimization in bioreactors;
  • Solid-state bioreactors: development and challenges.

Dr. Serena Lima
Prof. Dr. Francesca Scargiali
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • bioreactor design
  • process intensification
  • CFD
  • mass transfer
  • innovative bioreactors
  • productivity, process optimization
  • solid-state bioreactors

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Published Papers (4 papers)

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Research

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23 pages, 16020 KiB  
Article
Comparison of Perfusion Culture Performance in Orbitally Shaken Bioreactors and Stirred Tank Bioreactors: A Spatiotemporal Dynamic Analysis of Shear Stress and Mass Transfer Based on Suspension Rheology
by Botao Zhang, Qingyuan Ran, Gance Dai, Qian Ye, Liang Zhao and Wen-Song Tan
Processes 2025, 13(4), 955; https://doi.org/10.3390/pr13040955 - 24 Mar 2025
Viewed by 420
Abstract
This study examines the differences in performance between orbitally shaken bioreactors (OSBs) and stirred tank bioreactors (STBs) in Chinese Hamster Ovary (CHO) cell perfusion culture in response to the growing market demand for monoclonal antibodies (mAbs). Although OSBs demonstrated higher cell densities, a [...] Read more.
This study examines the differences in performance between orbitally shaken bioreactors (OSBs) and stirred tank bioreactors (STBs) in Chinese Hamster Ovary (CHO) cell perfusion culture in response to the growing market demand for monoclonal antibodies (mAbs). Although OSBs demonstrated higher cell densities, a notable reduction in specific antibody production rates was observed during the mid-to-late phases of the culture compared with STBs. To elucidate the underlying mechanisms, the rheological behaviour of high-density cell suspensions in both reactor types was initially characterised, confirming their adherence to the Sisko fluid model. Computational Fluid Dynamics (CFD) analysis revealed the influence of these rheological properties on the shear stress distribution and mass transfer. This analysis identified the key limiting factors for achieving higher cell densities: mass transfer efficiency in OSBs and shear stress in STBs. Using an Euler–Lagrangian cell-tracking methodology to analyse cellular “lifelines”, it was determined that OSBs exhibited approximately twice the number and frequency of shear stress peak occurrences compared to STBs. This persistent mechanical stimulation likely contributes to the reduced specific antibody production rates observed. This comprehensive investigation not only clarifies the comparative advantages and limitations of different bioreactor types in perfusion culture but also provides a robust theoretical basis and technical guidance for informed reactor selection, optimisation, and scale-up in industrial production environments. Full article
(This article belongs to the Special Issue Bioreactor Design and Optimization Process)
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17 pages, 3127 KiB  
Article
Will Dissolved Hydrogen Reveal the Instability of the Anaerobic Digestion Process?
by Daniela Platošová, Jiří Rusín, Radek Svoboda and Markéta Vašinková
Processes 2025, 13(1), 126; https://doi.org/10.3390/pr13010126 - 6 Jan 2025
Viewed by 815
Abstract
Dissolved hydrogen is a critical factor in maintaining the delicate balance among microbial species that drive anaerobic digestion. Since previous findings have demonstrated a correlation between dissolved hydrogen concentration and volatile fatty acid (VFA) levels, we propose to evaluate the use of dissolved [...] Read more.
Dissolved hydrogen is a critical factor in maintaining the delicate balance among microbial species that drive anaerobic digestion. Since previous findings have demonstrated a correlation between dissolved hydrogen concentration and volatile fatty acid (VFA) levels, we propose to evaluate the use of dissolved hydrogen concentration in digestate as an alternative to traditional VFA measurements. The aim is to determine whether dissolved hydrogen could serve as a faster, more accurate, and more efficient indicator of process instability in anaerobic digestion. An integral part of this task also involves addressing the technical challenge of identifying a suitable sensor that meets our requirements. In this study, we evaluated the ratio of dissolved hydrogen concentration to Total Inorganic Carbon as a potential alternative to the traditional stability indicator, Volatile Fatty Acids/Total Inorganic Carbon (VFA/TIC), also referred to as Flüchtige Organische Säuren/Totales Anorganisches Carbonat (FOS/TAC). The single-stage anaerobic digestion process was carried out in a Terrafors IS rotary drum bioreactor for 150 days at an average temperature of 40 °C and an organic volatile load of 0.092 kg m−3 d−1. Corn silage was dosed on weekdays as the substrate. With a theoretical retention time of 45 days, a biogas production of 0.219 Nm3kgVs−1 with a CH4 content of 31.6% was achieved. The values of the determined VFA/TIC stability indicator ranged from 0.22 to 5.66, with the highest values obtained when the reactor was overloaded. The dissolved hydrogen concentration ranged 0.005–0.196 mg dm−3. The Pearson correlation coefficient was 0.337 and the Spearman correlation coefficient was 0.468. The amperometric microsensor has proven to be unsuitable for field applications due to its lack of sensitivity and short lifetime. The proposed ratio of dissolved hydrogen concentration to TIC did not prove to be significantly more effective than the established VFA/TIC indicator. Full article
(This article belongs to the Special Issue Bioreactor Design and Optimization Process)
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Review

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34 pages, 4220 KiB  
Review
Effects of Light Quality Adjustment in Microalgal Cultivation: Flashing Light and Wavelength Shifts in Photobioreactor Design
by Arima Marchese, Serena Lima, Alessandro Cosenza, Francesco Giambalvo and Francesca Scargiali
Processes 2025, 13(4), 1159; https://doi.org/10.3390/pr13041159 - 11 Apr 2025
Viewed by 570
Abstract
The distribution of light within a microalgal culture and the choice of the best wavelengths are considered the most critical aspects in the scale-up of microalgal culture. Several studies have investigated these features, resulting in a substantial body of literature that analyzes the [...] Read more.
The distribution of light within a microalgal culture and the choice of the best wavelengths are considered the most critical aspects in the scale-up of microalgal culture. Several studies have investigated these features, resulting in a substantial body of literature that analyzes the effects in terms of an increase in biomass production or shift in its composition. This work addresses two types of light quality adjustments: the application of flashing light and shifts in light wavelength. The effects on microalgal culture are examined. Later, the application of these light features to photobioreactor design is described. Specifically, three kinds of photobioreactors are examined: (1) reactors designed to minimize light gradients, (2) reactors where the geometry produces a flashing light effect on the cells and (3) reactors that use filters to obtain a shift in the sunlight wavelength. The results showed that both the effect of flashing lights and wavelength shift strongly depends on various parameters such as the alga taken into consideration, the light intensity, the agitation type, growth medium, light intensity and temperature and, regarding the flashing light also, the frequency and the duty cycle. Despite all these specific differences, this work aims to resume and provide specific instruments for choosing operational parameters in microalgal cultivation and in photobioreactor design to achieve targeted outcomes, such as an increase in biomass production or in high-value compound accumulation. Full article
(This article belongs to the Special Issue Bioreactor Design and Optimization Process)
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21 pages, 1353 KiB  
Review
Tackling Old Challenges in Microalgal Biotechnology: The Role of Photobioreactors to Advance the Technology Readiness Level
by Mariany Costa Deprá, Rosangela Rodrigues Dias, Leila Queiroz Zepka and Eduardo Jacob-Lopes
Processes 2025, 13(1), 51; https://doi.org/10.3390/pr13010051 - 29 Dec 2024
Viewed by 1482
Abstract
Microalgae biotechnology has taken the world by storm. However, despite its great potential promise, it still cannot be considered a fully consolidated technology due to a crucial challenge: the low rates of biomass productivity. To overcome this hurdle, photobioreactors have been developed as [...] Read more.
Microalgae biotechnology has taken the world by storm. However, despite its great potential promise, it still cannot be considered a fully consolidated technology due to a crucial challenge: the low rates of biomass productivity. To overcome this hurdle, photobioreactors have been developed as an innovative solution, promising to increase the efficiency of microalgae cultures by providing optimized conditions. However, the results obtained with these systems do not always meet initial expectations, and their large-scale implementation faces complex technical challenges. In light of this, the present review addresses the main aspects related to the design and engineering of photobioreactors, highlighting their potentialities and limitations in overcoming the critical challenges of microalgal biotechnology. Furthermore, we discuss the current technological readiness level and the commercial readiness index of microalgae-based bioproducts from the perspective of industrial-scale production. Full article
(This article belongs to the Special Issue Bioreactor Design and Optimization Process)
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