Immobilized cell reactor experiment experimental reactor system

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1. IMMOBILIZED CELL REACTOR EXPERIMENTS-EXPERIMENTAL REACTOR SYSTEM TYPES PRESENTED BY: G.DILIP KUMAR M.EVANGELIN FLORA S.GAYATHRI

2. IMMOBILIZED CELL BIOREACTOR(ICB) These are the Bioreactors that involves Adsorption, Entrapment, Microcapsulation, covalent binding and cross-linking Following can be immobilized, Enzymes Viable cells Plant Cells Animal Cells

3. TYPES OF IMMOBILIZED BIOREACTORS Fixed/ Packed Bed Reactors Fluidized Bed Reactor Bubble – Column Reactor Trickle-Bed Reactor Airlift Reactor Systems--- Special type reactor system

4. PACKED-BED REACTOR Also known as Fixed-Bed Reactor Consists of cylinder of large diameter with multiple catalyst bed or many tubes in parallel packed with catalyst and encased in Large shell These reactors are widely used with immobilized cells These reactors Catalyze Gas Reactions

5. Purpose - Synthesis of Large scale basic Chemicals & Intermediates Reaction type- Heterogeneously Catalyzed Gas Reactions take part on surface of catalyst Catalyst Forms Used: Chemisorption or Active centers Surface Reactions Desorption of products Back Diffusion of products into Gas Space

6. Catalyst Used: Granular/Granules Pellets Cylindrical or Spherical Gas Flow- Continuously through Stationary bed Large Size Catalyst Particles- For low pressure Drop

7. Packing- Provide Good Contacting Phase Chemical Reaction- Takes place on surface of catalyst Three types of Packed/Fixed Bed Reactors: Single-Bed Reactor Multi-Bed Reactor Multi-Tube Reactor

8. SINGLE-BED REACTOR- All particles are located in the same vessel MULTI-BED REACTOR- Several serial Bed with intermediate cooling/ heating stages MULTI-TUBE REACTOR- Several tubes of Small diameter filled with Particles

9. ADVANTAGES Higher conversion per unit mass of catalyst than other catalytic reactors Low operating cost Continuous operation Catalysts stays in the reactor Reaction mixture/catalysts separation is easy Effective at high temperature & pressures DISADVANTAGES Undesired heat gradients Poor temperature control Difficult to clean Difficult to replace catalyst Undesirable side reactions

10. FLUIDIZED BED REACTOR Type of reactor used to carry out Multiphase Chemical Reactions Fluidization- Operation by which solids are caused to behave like a fluid by blowing gas or liquid upwards through the Solid-filled reactor Material Fluidized- Solid Fluidizing Medium- Gas or Liquid Purpose- solid separation, Fluid-catalytic cracking , Fluidized bed combustion, Heat or mass transfer or interface modification

11. REACTION PROCESS: Combination of attached Growth & Suspended Growth Cylindrical with perforated distribution plates and conical entry sections Slime Film- This is biological film that is developed and maintained on Solid support Catalyst Used- Tiny Granules

12. Purpose- solid separation, Fluid-catalytic cracking Fluidized bed combustion, Heat or mass transfer or interface modification Intermediate between CSTR and PBR TYPES- Circulating Fluidized Bed(CFR)& Fixed Fluidized Bed(FFR) CFR- Both in Axial & Radial ozone concentration is present, For lower emission of pollutants FFR- Catalyst remains stationary until discarded, due to plugging and high pressure drop

13. ADVANTAGES Uniform particle mixing Uniform temperature gradients Ability to operate reactor in continuous state DISADVANTAGES Increased reactor vessel size Pumping requirements & pressure drop Particle entrainment Lack of current understanding Erosion of internal components Pressure loss scenarios

14. BUBBLE-COLUMN REACTOR Has large aspect Ratio- Those with High Height to Diameter Ratio which takes forms of column instead of more squat tanks MIXING- Forcing Compressed Gas that rises through the liquid OPERATION- Batch or Continuous mode with co-current or countercurrent flow of liquid relative to rising Gas Large conversion- High height to Diameter Ratio reactors

15. BUBBLE COLUMN- Are Multiphase contactors CONSTRUCTION- Cylindrical vessel with Gas distributor at bottom Liquid- Flows from top part of reactor and Gas- Flows from bottom part of reactor of the reactor cross-section GAS- Sparged in form of bubbles into liquid-liquid or liquid-solid phase

16. Length to Diameter ratio : -Normal Reactors- Atleast 5 -Biochemical Reactors- Between 2 and 5 THREE MAIN PHENOMENA OF DESIGN & SCALE-UP: Heat & Mass transfer characteristics Mixing characteristics Chemical kinetics of Reactor systems

17. HYDRODYNAMIC PARAMETERS: Specific gas-liquid interfacial area Sauter mean bubble diameter Overall Heat-transfer coefficient between slurry and immersed heat transfer internals Mass transfer coefficients for all species Gas hold-ups Physiochemical properties of liquid medium

18. ADVANTAGES Excellent Heat and Mass-transfer characteristics and coefficients Have high volumetric productivity Better utilization of Plate area and flow Self regulating DISADVANTAGES Less efficient than other Bioreactors Does not have Draft tube Higher Catalyst consumption than others Higher installation costs and difficult to Design

19. TRICKLE-BED REACTOR Three phase reactor systems containing a packed bed of heterogeneous catalyst and flowing gas and liquid phases Depends One or more reactant is provided in each feed liquid and gas phase Biochemical Reaction- Depends on contacting of fluid , Containing sparingly soluble reactant Performance- Influenced by physical state of gas-liquid flow through the Bed

20. PHYSICAL CHARACTERISTICS: Surface Area of Packaging Efficiency of wetting of catalyst by flowing liquid phase Gas-Liquid flow pattern Mass transfer of sparingly soluble reactants from gas to liquid phase Mass transfer of both reactants to the catalyst surface If it is porous/permeable catalyst , diffusion of reactants to intraparticle catalytic sites may occur

21. PROCESS: The gas and liquid co-currently flow downward over a fixed bed of catalyst particles Liquid trickles down, while Gas phase is continuous In trickle bed, various flow regimes are distinguished, depending on gas and liquid flow rates , fluid properties and packing characteristics

22. REACTION TYPE: Co-current- Downward movement of liquid Counter-current- Downward or upward movement of gas over a packed bed of Particles(Catalyst) Liquid is s prayed onto the top of packing and trickles down through the beds in small rivulets

23. ADVANTAGES Opportunity to develop continuous process Better control possibilities Higher productivity Possibility of conducting multi-phase reactions Refined research tool for enzyme mechanism DISADVANTAGES Leakage of enzymes Fouling Loss of enzyme activators or cofactors Concentration polarization Deactivation of enzyme by shear-related effects

24. AIRLIFT REACTOR SYSTEMS Typical motionless Bioreactor where the Internal Circulation and Mixing are achieved by bubbling Air EMPLOY- Forced/ Pressurized air to circulate cells and nutrient medium GAS STREAM- Facilitate exchange of material between the gas phase and the medium OXYGEN- Usually transferred to the liquid Unwanted (Accumulated) products are removed through exchange with gas phase

25. STRUCTURE/DESIGN: Entire reactor is divided into 2 halves by Draft tube, RISER- Inner GASSED Region, has Gas Injection connected and Air moves upwards DOWN COMER - Outer GASSED Region, Has Degassed media and cells Mean-Density Gradient- Between Riser and Down comer causes continuous Circulation

26. PARTS: -BASE- Connected to Perforated Nozzle Bank/Plate/ Sparger to pump pressurized air -HEADSPACE- Gas release region, flocculation, foam accumulation etc GAS SEPERATOR: * Facilitates gas/liquid recirculation *Maximizes gas residence time *Reduces gas friction in down comer

27. TYPES: INTERNAL LOOP ALR: Baffles are placed strategically in a single vessel create the channels required for the circulation -Shortest part that a bubble cover from the riser to down comer in a straight line EXTERNAL LOOP ALR: Circulation takes place through separate and distinct conduits There is usually a minimum horizontal distance to be covered , increases the chance of disengagement of the bubbles

28. ADVANTAGES Simple design with no moving parts Less Maintenance Less risk defects DISADVANTAGES Greater Air throughput and Higher Pressure needed Inefficient break the foam when Foaming occurs Bubble breakers are Absent