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Main function : to provide a controlled environment for the growth of a microorganism, or a defined mixture of microorganisms, to obtain a desired product.
6) Aseptic equipment design. 7) Control of bioreactor environment (both macro and micro-environments). 8) Implication of bioreactor design on downstream product separation. 9) Capital and operating costs of the bioreactor. 10) Potential for bioreactor scale up.
Most important bioreactor for industrial application (Low capital and operating cost). However, no single system adequately meets the needs all biological systems can be constructed.
Laboratory scale bioreactors liquid volume < 10 L constructed out of Pyrex glass.
For larger bioreactors, stainless steel is used. Stainless steel = refers to various alloys of primarily iron, nickel and chromium. Different grade of SS = 302, 304, 316, 318. (higher the number, the greater the resilience of the steel.
316 L most widely used (L indicates the steel has low carbon content). The stainless steel used in bioreactors are polished to a mirror finish (makes cleaning and sterilization easier). Components joined in an oxygen-free environment to avoid corrosion, displaced by argon (TIG technique, Total Inert Gas)
Geometry measurement of stirred tank bioreactor A mechanically stirred tank bioreactor fitted with a sparger and a Rushton turbine impeller will typically have relative dimensions (Table 1)
Height of liquid in reactor to HL/Ht height of reactor Height of reactor to diameter Ht/Dt of tank Diameter of impeller diameter in tank to Da/Dt
Diameter of baffles to diameter Db/Dt of tank Impeller blade height diameter of impeller Impeller blade width diameter of impeller to W/Da to L/Da
Distance between middle of E/W impeller blade and impeller blade height
A tank's height:diameter ratio is often referred to as its aspect ratio. A stirred tank bioreactor is approximately cylindrical in shape. It has a total volume (Vt) of 100,000 litres. The geometry of the reactor is defined by the following ratios:
Dt:Ht Da:Dt Db:Dt 0.50 0.33 0.10
Ex: A cylindrical reactor has a liquid volume of 100,000 L. It has an aspect ratio of 1:1. The height of the liquid in the reactor will be approximately.?? (Ans:5.03m)
An agitator system
An oxygen delivery system A foam control system A temperature control system A pH control system Sampling ports A cleaning and sterilization system. A sump and dump line for emptying of the reactor.
Function:
provide good mixing and thus increase mass transfer rates through the bulk liquid and bubble boundary layers. provide the appropriate shear conditions required for the breaking up of bubbles.
Stirred vessels > 10 L volume, mechanical drive coupling together with rotating mechanical seals. Seal components: carbon and ceramic. Laboratory scale: simple rotating mechanical seal. Larger scale: double-action rotating mechanical seals; achieving longer operation times. The rotating mechanical seal must be free from cracks and the cavities between the packing must be steamable.
- Improvement of the heat transfer at the heat transfer surfaces for dissipating the heat generated by the biological reaction and mechanical work.
Multi-blade disc impellers- produce radial flow and high energy dissipation density in the proximity of the agitator. Propeller impellers- create an axial flow (for mammalian cell cultivation), low shear forces in connection with low oxygen requirements are applicable INTERMIG impellers- create both radial and axial flows, for high viscous media or products
Kaplan Turbine normally for loop systems(mixing effect is achieved by circulating the liquid) EKATO INTERPROP improved heat and mass transfer, high dispersion of drops and bubbles, homogenous distribution of solid particles as well as low investment costs.
Agitators characteristics:
Radial Flow - the liquid flow from the impeller is initially directed towards the wall of the reactor Axial Flow - The liquid flow from the impeller is directed downwards towards the base of the reactor
Radial flow impellers (contain two or more impeller blades which are set at a vertical pitch)
Function of Rushton turbine impeller. Mixing is achieved with the use of baffles. higher input energy Mixing is not efficient as axial flow mixing
Unbaffled bioreactor. Note the presence of a large vortex. The liquid is circulating around the impeller.
Baffled bioreactor. Note the presence of small bubbles from gas entrainment and the absence of a large vortex.
Baffles break the liquid flow lines causing the formation of turbulent eddies.
A compressor forces the air into the reactor, need sufficient pressure to force the air; for large reactors, produce air at 250kPa.The air should be dry and oil free so as to not block the inlet air filter (not to use instrument air)
Large bioreactor (> 1000L) pleated membrane filters housed in polyproplylene cartridge. By pleating the membrane, it is possible to create a compact filter with a very large surface area for air filtration. Large scale membrane filtration is very expensive process. filtration is not possible; too expensive; Heat sterilisation (steam is use to sterilize the air)
For small reactor, the exit air system, will include a condenser.
Condenser simple heat exchanger through which cool water is passed; minimize water evaporation and the loss of volatiles; Drying the air also prevents blocking the exit air filter with water
AIR SPARGER
The air sparger breaks the incoming air into small bubbles The sparger must located below the agitator to facilitate bubble break up
Ring Sparger
speed
Fast impeller
Slow impeller speed bubbles will not be broken, rise directly to to the surface, accumulate and coalesce under impeller leading to from large bubbles and low oxygen transfer rates. Fast speed smaller bubbles will be generated, move throughout the reactor increasing the gas hold up and bubble residence time.
Volume per volume per minute, vvm. The airflow rate and liquid volume must have the same basal unit. The air flow rate must be expressed in terms of volume per min.
CONDENSOR TEMPERATURE
A cold condenser temperature can help to control the foam. The density of the foam increases when it moves from the warm headspace volume to the cold condenser region. This causes the foam to collapse
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