Bioreactor insert and biofilm support, related apparatus and related methods

A method for forming a bioreactor product, the method comprising:

• providing a bioreactor comprising:
• a reaction vessel defining an interior reaction volume;
• and
• a bioreactor insert apparatus mounted within the reaction vessel, the bioreactor insert apparatus comprising:
• an inlet volume in fluid communication with a first fluid inlet;
• an outlet volume in fluid communication with a first fluid outlet;
• a plurality of exit volumes, each exit volume being in fluid communication with the inlet volume and comprising at least one exit biofilm support disposed at a boundary between the exit volume and an external volume outside the bioreactor insert apparatus, wherein:
• the exit biofilm support is adapted to promote growth, attachment, and metabolism of microorganisms in the form of a biofilm thereon, and the exit biofilm support is adapted to permit fluid and solid transport across the exit biofilm support and between the exit volume and the external volume;
• and
• a plurality of recirculation volumes, each recirculation volume being in fluid communication with the outlet volume and comprising at least one recirculation biofilm support disposed at a boundary between the recirculation volume and the external volume outside the bioreactor insert apparatus, wherein:
• the recirculation biofilm support is adapted to promote growth, attachment, and metabolism of microorganisms in the form of a biofilm thereon, and the recirculation biofilm support is adapted to permit fluid and solid transport across the recirculation biofilm support and between the recirculation volume and the external volume;
• wherein:
• the external volume corresponds to a portion of the interior reaction volume outside the bioreactor insert apparatus,
• the bioreactor insert apparatus further comprises biofilms adhered to the biofilm supports, the biofilms having biological activity,
• an aqueous reaction medium at least partially fills the interior reaction volume and the bioreactor insert apparatus, and
• suspended microorganisms are present in the aqueous reaction medium;
• feeding an influent stream comprising one or more reactants for conversion to the bioreactor insert apparatus via the first fluid inlet;
• circulating the influent stream through the inlet volume, into the exit volumes, through the exit biofilm supports and biofilms thereon, into the external volume, through the recirculation biofilm supports and biofilms thereon, into the recirculation volumes, into the outlet volume, and through the first fluid outlet;
• and
• converting the one or more influent reactants to a product.