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The growth of microorganisms in fermentations where oil had been maintained as the continuous phase was examined to determine whether advantage could be gained from the increased solubility of oxygen in hydrocarbon. Although cell concentrations were highest in the aqueous phase of oil‐continuous systems, due to the large oil fraction, productivities achieved per unit fermenter volume were generally equivalent to those obtained from water‐continuous systems. With the oil‐continuous emulsions, the power requirement for aeration and mixing was less, and phase reversal resulted in a threefold concentration of cells in the aqueous medium, thereby facilitating their recovery.

The energy consumption of a fermenter constitutes a major part of the operating expense of a single cell protein process. A low-pressure airlift fermenter was designed to reduce this cost. In this new design, the fermenter broth is kept below 120 cm in depth, and air alone is employed to fulfill the need of supplying oxygen, and cooling and agitating the broth. The use of low-pressure air from air blowers instead of air compressors lowers the capital cost of air delivery and reduces the energy consumption in the fermenter section to below 1 kWh/kg protein, a saving of over 70% as compared to a conventional stirred tank fermenter. It also eliminates the investment of mechanical agitators, heat exchangers, and air compressors. Sulfite oxidation studies confirmed the design concepts.

Experiments using Pichia yeast grown on n-paraffins have been conducted in laboratory 10-L airlift fermenters and in a 640-L module of commercial scale. Results confirmed the design concept of combining oxygen transfer and fermenter cooling with low-pressure air. However, in the absence of mass transport constraints, the build up of toxic factors in the fermenter appeared to be a major variable limiting cell productivity. Foaming in the large fermenter also presented a serious problem, which must be solved before low-pressure airlift fermenters become practical.