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Alternating gas and liquid delivery to immobilized cells eliminates mass transfer limitations to maximize bioprocessing productivity.

With the increasing need for renewable fuels and chemicals, energy-efficient, localized production becomes critical to facilitate a global economic, green transition. The status quo of thermo-catalytic processes, such as the Fischer-Tropsch or Haber-Bosch reactions, based on input molecules passed over catalysts at high pressures (up to 25 MPa) and high temperatures (up to 500掳C), are extremely energy intensive and non-selective, and require product separation. In addition, they are unable to address stranded assets 鈥� resources that are widely dispersed 鈥� and require a sizeable minimum input of waste resources. However, newer, electrocatalytic processes face rising costs of electricity due to the demand for artificial intelligence (AI) as well as electrification of transportation and heating. Such physical processes fundamentally cannot compete against fossil products on a cost basis.

These issues can be addressed using bioprocessing. Specifically, natural and genetically modified microbes can convert waste gases into valuable products, from methanol to biosurfactants to acetate, through the process of gas fermentation. Microbes have naturally evolved over millennia to operate extremely efficiently at ambient temperatures (25鈥�40掳C) and pressures (0.07 MPa), often resulting in selective conversions without byproducts, minimizing product separation needs. As living organisms with exponential growth, microbes also serve as cheap, easily replenishable biocatalysts.

The key challenge of gas fermentation is not the microbe and its conversion ability but rather one of bioreactor design to address the mass transfer of gases. This article discusses the impediments of mass transfer and supply chain resilience in existing gas fermentation processes and explores a novel bioreactor design that addresses the challenges of intermittency, modularity, and scale-up...