DESIGN OF BIOPROCESS VESSELS-fermentation technology.pptx

This is an extensive presentation about the design of bioreactor and fermentors, also called bioprocess vessels. it contains all the components of a bioreactor such as the aeration system, the agitation system and the seals etc.

1. DESIGN OF BIOPROCESS VESSELS ANJISHNU MUKHOPADHYAY BTN/20/704 CC-11 PAPER

2. WHAT IS A BIOREACTOR? A bioreactor is a type of  BIOPROCESS  vessel that is used for the production of various chemicals and biological reactions. It is a closed container with adequate arrangement for aeration, agitation, temperature and pH control, and drain or overflow vent to remove the waste biomass of cultured microorganisms along with their products.

3. CONTINOUS TANK STIRRED FERMENTOR THIS IS THE MOST COMMONLY USED FERMENTOR AND WILL BE USED AS THE MODEL FOR THIS PRESENTATION

4. Features of a bioprocess vessel ABLE TO MAINTAIN ASEPTIC CONDITION FOR A LONG PERIOD. CAPABLE OF PROPER AGITATION AND AERATION OF THE MEDIA. CAPABLE OF HIGHLY ACCURATE MESUREMENT AND MAINTAINENCE OF PHYSICAL CONDITIONS SUCH AS TEMPERATURE, ph, PRESSURE ETC. ABLE TO PERFORM FOR A LONG DURATION. IS ENERGY, POWER AND LABOUR EFFICIENT.

5. CONSTRUCTION MATERIAL BOROSILICATE GLASS USED FOR SMALL SCALE FERMENTERS. STAINLESS STEEL USED FOR LARGE SCALE FERMENTERS. USUALLY, 10 TO 13% CHROMIUM ADDED TO STEEL TO MAKE IT CORROSIVE-PROOF. MUST BE NON TOXIC .

6. PARTS OF A BIORECTOR

7. FERMENTER VESSEL MUST BE LARGE FOR HIGH SCALE PRODUCTION. MUST TO STRONG ENOUGH TO WITHSTAND HUGE WEIGHTS AND PRESSURE. MUST HAVE NECESSARY EQUIPMENTS AND PORT ATTACHMENTS.

8. NUMEROUS STAINLESS STEEL FERMENTERS

9. HEATING/COOLING APPARATUS TEMPERATURE MUST BE OPTIMUM. ALSO NECESSARY FOR STERILISATION . USUALLY HAVE HEATING OR COOLING JACKETS (THERMOSTATICALLY CONTROLLED). INTERNAL HEATING COILS MAY ALSO BE PRESENT.

10. COOLING JACKET FOR SMALL SCALE BEER FERMENTER

11. AERATION SYSTEM(SPARGERS) ADEQUATE AERATION NECESSARY FOR AEROBIC BIOREACTIONS. SPARGERS ARE DEVICES USED TO ACHIEVE THAT. IT INTRODUCES AIR INTO THE VESSEL. AIR MUST BE STERILISED AND CLEANED BEFORE ENTRY. USUALLY ASSOCIATED WITH THE IMPELLER SHAFT.

12. TYPES OF SPARGERS POROUS SPARGER MADE OF STINTERED GLASS. HAS A POROUS TEXTURE. AIR PRESSURE IS USUALLY LOW. USED USUALLY IN SMALL SCALE FERMENTERS. MICROBIAL GROWTH CAN AFFECT AIR FLOW. ORIFICE SPARGER USED IN SMALL STIRRER TANKS. CONSISTS OF A RING OF PERFORATED PIPE AROUND THE IMPELLER. USED IN YEAST PRODICTION, EFFLUENT MANAGEMENT ETC. NOZZLE SPARGER USED IN INDUSTRIAL SCALE. CANTAINS A SINGLE OPENING. CAN BE OPENED TO NUMEROUS DEGREES TO CONTROL AIR PRESSURE. ARE USUALLY BELOW THE IMPELLERS.

13. TYPES OF SPARGERS POROUS SPARGER ORIFICE SPARGER NOZZLE SPARGER

14. SEALING ASSEMBLY HGHLY NECESSARY TO MAINTAIN ASEPTIC CONDITION. HIGHLY CHALLENGING IN LARGE SCALE FERMENTERS. EVEN ENTRY OF LITTLE BIT OF AIR IS UNDESIRED IN CASE OF ANAEROBIC FERMENTATIONS. THUS SEALING ASSEMBLY IS VERY IMPORTANT.

15. TYPES OF SEALING ASSEMBLY STUFFING BOX IMPELLER SHAFT IS SEALED WITH RINGS AND LAYERS OF ASBESTOS OR COTTON YARN. HIGH STIRRER SPEED CAN WEAR OUT THE PACKING DIFFICULT TO STERILIZE. USED IN SMALL SCALE FERMENTERS. MECHANICAL SEAL USED IN BOTH SMALL AND LARGE SCALE FERMENTERS. HAS TWO PARTS: STATIONARY BEARING HOUSING & ROTATING ATTACHMENT WITH SHAFT. LUBRICATED WITH STEAM CONDENSATE. MAGNETIC SEAL CONTAINS TWO SETS OF MAGNETS: A DRIVING & A DRIVEN MAGNET. IS STRONGER THAN OTHER FORMS OF SEALS. CAN EASILY WORK WITH HIGH IMPELLER SPEEDS.

16. TYPES OF SEALING ASSEMBLY STUFFING BOX MECHANICAL SEAL MAGNETIC SEAL

17. BAFFLES THEY ARE METAL STRIPS ATTACHED ON THE INTERNAL WALLS OF THE FERMENTER. THEY ARE USUALLY 1/10 TH OF THE TOTAL INTERNAL DIAMETER OF THE FERMENTER. THEY PREVENT VORTEX FORMATION AND INPROVE AERATION AND MIXING.

18. BAFFLES ATTACHED TO THE INTERNAL WALL OF FERMENTER

19. AGITATORS(IMPELLERS) AGITATION AND MIXING IS NECESSARY FOR INCREASED EFFICIENCY. AGITATION IS ALSO RECEIVED WITH PROPER AGITATION. IMPELLERS ARE DEVICES THAT AGITATE THE MEDIUM, USUALLY THROUGH RAPID ROTATION.

20. TYPES OF IMPELLERS DISC TURBINE CONSISTS OF A DISC AND A SERIES OF RECTANGULAR VANES. VANES ARE JOINED ON THE VERTICAL PLANE. VANED DISC ALSO CONTAINS A DISC AND RECTANGULAR VANES BUT HERE, THE VANES ARE CONNECTED TO THE UNDERSIDE OF THE DISC. OPEN TURBINE DOES NOT CONTAIN A DISC. VANES ARE DIRECTLY CONNECTED TO THE SHAFT.

21. TYPES OF IMPELLERS DISC TURBINE VANED DISC OPEN TURBINE

22. FOAM CONTROL FOAM FORMATION MUST BE PREVENTED OR AT LEAST MINIMISED. IT CAN RESULT IN DECREASED EFFICIENCY AND EVEN CONTAMINATION. CONTROLLED BY TWO UNITS: FOAM SENSOR FOAM CONTROL UNIT

23. TWO PARTS OF THE FOAM CONTROL UNIT

24. FEED PORTS AND OUTLETS PIPELINES AND TUBES CONNECTED TO NUTRIENT RESERVOIRS. CAN ALSO BE USED TO ADD INOCULUM, ACID, ALKALI ETC. USUALLY HEAT STERILIZED IN SITU. ARE USUALLY MADE UP OF SILICONE. MAY ALSO BE FEEDING COLD/HOT WATER TO COOLING/HEATING JACKETS. OUTLETS ARE USED TO REMOVE MEDIA.

25. VALVES USED TO CONTROL FLOW OF LIQUIDS THROUGH PORTS. CAN ALSO BE NECESSARY FOR SAFETY AGAINST EXPLOSIONS. THERE ARE USUALLY 4 TYPES: GLOBE VALVE BUTTERFLY VALVE BALL VALVE DIAPHRAGM VALVE

26. USE OF COMPUTERS AND AUTOMATIC SENSORS NOWADAYS, MOST FUNCTIONS IN LARGE SCALE FERMENTERS ARE AUTOMIZED WITH THE USE OF SENSORS AND COMPUTERS. THUS ALSO RESULTS IN CREATION OF PERFECT DATABASES OF THE NUMEROUS CHANGES OCCURING THROUGHOUT THE FERMENTATION PROCESS. THUS PREDICTIONS REAGARDING THE QUALITY OF THE PRODUCT AND THE AMOUNT OF WASTE CAN ALSO EASILY BE MADE.

27. REFERENCES Stanbury PF, Whitaker A, Hall SJ (1900). Principle of Fermentation Technology. Butterworth-Heinemann Fermentation (Industrial). massey. ac.nz Bailey, j.e: OLLIS, D.F (2006). Biochemical Engineering Fundamentals (2nd ed.). New York: Mc Graw Hill Publication-ISBN 978-0-07-003212-5

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