One approach of Power-to-X is the coupling of the energy and chemical sector, using electrolysis for syngas generation and microbial gas conversion for the production of biochemicals. On the verge of commercialization, known challenges of gas fermentation technology are poor mass transfer of syngas, low cell concentration and productivity. These problems can be addressed by an intelligent reactor design. Thus, this article provides an overview on the current state of the art for reactor technology in syngas fermentation and discusses possible concepts with regard to an application at industrial scale.

Low productivities of bioprocesses using gaseous carbon and energy sources are usually caused by the low solubility of those gases (e.g., H2 and CO). It has been suggested that increasing the partial pressure of those gases will result in higher dissolved concentrations and should, therefore, be helpful to overcome this obstacle. Investigations of the late 1980s with mixtures of hydrogen and carbon monoxide showed inhibitory effects of carbon monoxide partial pressures above 0.8 bar. Avoiding any effects of carbon monoxide, we investigate growth and product formation of Clostridium ljungdahlii at absolute process pressures of 1, 4, and 7 bar in batch stirred tank reactor cultivations with carbon dioxide and hydrogen as sole gaseous carbon and energy source. With increasing process pressure, the product spectrum shifts from mainly acetic acid and ethanol to almost only formic acid at a total system pressure of 7 bar. On the other hand, no significant changes in overall product yield can be observed. By keeping the amount of substance flow rate constant instead of the volumetric gas feed rate when increasing the process pressure, we increased the overall product yield of 7.5 times of what has been previously reported in the literature. After 90 h of cultivation at a total pressure of 7 bar a total of 4 g L−1 of products is produced consisting of 82.7 % formic acid, 15.6 % acetic acid, and 1.7 % ethanol.

Gasification of organic matter under the conditions of supercritical water (T > 374 °C, p > 221 bar) is an allothermal, continuous flow process suitable to convert materials with high moisture content (<20 wt.% dry matter) into a combustible gas. The gasification of organic matter with water as a solvent offers several benefits, particularly the omission of an energy-intensive drying process. The reactions are fast, and mean residence times inside the reactor are consequently low (less than 5 min). However, there are still various challenges to be met. The combination of high temperature and pressure and the low concentration of organic matter require a robust process design. Additionally, the low value of the feed and the product predestinate the process for decentralized applications, which is a challenge for the economics of an application. The present contribution summarizes the experience gained during more than 10 years of operation of the first dedicated pilot plant for supercritical water gasification of biomass. The emphasis lies on highlighting the challenges in process design. In addition to some fundamental results gained from comparable laboratory plants, selected experimental results of the pilot plant “VERENA” (acronym for the German expression “experimental facility for the energetic exploitation of agricultural matter”) are presented.

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