Biofilms have also been considered for the production of bulk chemicals using biofilm fermentation. Some products are manufactured using immobilized biocatalysts. However, immobilization methods can be expensive, and the process can deactivate the biocatalyst, resulting in a decrease in activity over time. These factors make it challenging to use immobilized biocatalysts to produce bulk chemicals and fuels that typically have lower market prices. Therefore, biofilm fermentation is considered a way to increase the yield of organic acids and alcohols in a more commercially viable manner. Bacterial strains known for producing chemicals of interest are grown on carriers that can be made from a variety of materials.
Start-up times for biofilm reactors are typically long, as it may take several days for bacteria to attach to the carrier. In addition, it may take weeks or even months to accumulate a sufficient amount of biomass. In contrast, excessive biomass growth can also clog the bioreactor, leading to downtime for maintenance and lost profits. Process operation and control is also challenging for the dynamic environment of the bioreactor.
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