The production of ethanol from industrial dry-milled torn starch was studie
d in a laboratory-scale fluidized-bed bioreactor using immobilized biocatal
ysts. Saccharification and fermentation were carried out either simultaneou
sly or separately. Simultaneous saccharification and fermentation (SSF) exp
eriments were performed using small, uniform kappa-carrageenan beads (1.5-2
.5 mm in diameter) of co-immobilized glucoamylase and Zymomonas mobilis. De
xtrin feeds obtained by the hydrolysis of 15% dry-milled corn starch were p
umped through the bioreactor at residence times of 1.5-4 h. Single-pass con
version of dextrins ranged from 54-89%, and ethanol concentrations of 23-36
g/L were obtained at volumetric productivities of 9-15 g/L-h. Very low lev
els of glucose were observed in the reactor, indicating that saccharificati
on was the rate-limiting step. In separate hydrolysis and fermentation (SHF
) experiments, dextrin feed solutions of 150-160 g/L were first pumped thro
ugh an immobilized-glucoamylase packed column. At 55 degrees C and a reside
nce time of 1 h, greater than 95% conversion was obtained, giving product s
treams of 162-172 g glucose/L. These streams were then pumped through the f
luidized-bed bioreactor containing immobilized Z. mobilis. At a residence t
ime of 2 h, 94% conversion and ethanol concentration of 70 g/L were achieve
d, resulting in an overall process productivity of 23 g/L-h. At residence t
imes of 1.5 and 1 h, conversions of 75 and 76%, ethanol concentrations of 4
9 and 47 g/L, and overall process productivities of 19 and 25 g/L-h, respec
tively, were achieved.