BACKGROUND: A single-stage reactor, in which the growth of bacterial culture, induction of desulfurizing enzymes, and desulfurization reaction are carried out in a single step, was adopted to investigate desulfurization of dibenzothiophene (DBT) at high cell densities. Rhodococcus erythropolis, IGTS8 was used as the biocatalyst. Optimal conditions for bacterial growth and DBT desulfurization were investigated. RESULTS: Optimization of fermentation conditions was necessary to obtain high cell densities including controlling accumulation of acetate. Under optimal operating conditions, the maximum optical density at 600 nm (OD600) was measured to be 26.6 at 118 h of cultivation. When biodesulfurization of DBT in model oil with a high cell density culture of IGTS8 was investigated, accumulation of sulfate was found to limit the extent of desulfurization. A sulfate removal step was added to obtain a single-stage integrated biodesulfurization process. Sulfate removal was achieved via an aqueous bleed stream and use of a separation unit to recycle the organic phase. CONCLUSION: A proof of principle of a complete system capable of biocatalyst growth, induction, desulfurization and by-product separation was demonstrated. This system enables simplification of the biodesulfurization process and has potential to lower the operating cost of the bioprocess. (c) 2008 Society of Chemical Industry.