bioreactor designyusronsugiarto.lecture.ub.ac.id/files/2014/04/bioreactor...reactor bioreactor any...
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BIOREACTOR DESIGNYUSRON SUGIARTO
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Bioreactor: device, usually a vessel, used to direct the activity ofa biological catalyst to achieve a desired chemicaltransformation.
Product
Bioreactor
Recycle
Product
separation & purification
Nutrients tank
Waste
Input
Pre-filtration
Fermenter: type of bioreactor in which the biocatalyst is a living cell.
What is a bioreactor?
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WHAT IS BIOREACTOR DESIGN?
Biotechnology:Application-oriented integration of biodisiplinesand engineering
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WHAT IS THE AIM OF BIOREACTOR DESIGN?
MINIMIZATION OF THE COSTS OF THE PERTINENT PRODUCT WHILE RETAINING THE DESIRED QUALITY AND THIS WITHIN THE BIOLOGICAL AND TECHNOLOGICAL CONSTRAINTS.
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1. Aerobic bioreactor: Need adequate mixing and aeration
2. Anaerobic bioreactor: no need for sparging or agitation
Challenges in Bioreactor Design
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REACTOR BIOREACTOR
any manufactured or engineered device or system that supports a biologically active environment.
vessels designed to contain chemical reactions a vessel in which a chemical process is carried out which involves organisms or biochemically active substances derived from such organisms
The design of a chemical reactor deals with multiple aspects of chemical engineering.
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REACTOR CONCEPTS
• The batch reactor
• The fed batch reactor
• The continuous flow, stirred tank reactor (CSTR)
• The plug flow reactor
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1. Bioreactor configurations
2. Bioreactor operation modes
3. Practical considerations for bioreactor design
Outline of Lecture
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BIOREACTOR TYPES
• The stirred vessel
• The bubble colomn
• The air lift
• The packed bed
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Bioreactor Configurations1. Stirred tank
Mixing method: Mechanical agitation
•Baffles are usually used to reduce vortexing
• Applications: free and immobilized enzyme reactions
•High shear forces may damage cells
•Require high energy input
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Bioreactor Configurations2. Bubble column
Mixing method: Gas sparging• Simple design•Good heat and mass transfer•Low energy input
Gas-liquid mass transfer coefficients depend largely on bubble diameter and gas hold-up.
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Bioreactor Configurations3. Airlift reactor
Mixing method: airlift• Compared to bubble column reactors, in an airlift reactors, there are two liquid steams: up-flowing and down-flowing steams. Liquid circulates in an airlift reactor as a result of density difference between riser and downcomer.
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Bioreactor Configurations4. Packed-bed reactor
Packed-bed reactors are used with immobilized or particulate biocatalysts.
Medium can be fed either at the top or bottom and forms a continuous liquid phase.
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Bioreactor Configurations5. Trickle-bed reactor
The trickle-bed reactor is another variation of the packed bed reactors.
Liquid is sprayed onto the top of the packing and trickles down through the bed in small rivulets.
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Bioreactor Configurations6. Fluidized bed reactor
When the packed beds are operated in upflow mode, the bed expands at high liquid flow rates due to upward motion of the particles.
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1. Bioreactor configurations
3. Practical considerations for bioreactor design
Outline of Lecture
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Bioreactor Operation Modes1. Batch Operation
A batch bioreactor is normally equipped with an agitator to mix the reactant, and the pH of the reactant is maintained by employing either buffer solution or a pH controller
trCCC
CK ss
s
sm max0
0ln Change of Cs with time, t
Batch operation with stirring
•A foam breaker may be installed to disperse foam
Sm
Ss
CK
Cr
dt
dCr
max
Substraterate
Biocatystconcentration
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Bioreactor Operation Modes2. Plug-flow mode
In a plug-flow reactor, the substrate enters one end of a cylindrical tube with is packed with immobilized enzyme and the product steam leaves at the other end.
trCCC
CK ss
s
sm max0
0ln
F, Cs0 F, Cs
t = 0F
V
An ideal plug-flow reactor can approximate the long tube,
packed-bed and hollow fiber or multistaged reactor
Residence time
Continuous operation without stirring
V
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Bioreactor Operation Modes3. Continuous stirred-tank
A continuous stirred-tank reactor (CSTR) is an ideal reactor which is based on the assumption that the reactants are well mixed.
Continuous operation with
stirring
F, Cs0
F, CsV
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Bioreactor Operation Modes3. Continuous stirred-tank reactor-Con.
dt
dCVVrFCFC s
sss 0
F, Cs0
F, CsV
Mass balance of substrate:
onAccumulati n ConsumptioOutput -Input
0dt
dCsSteady state:
Michaelis-Menten rate:
Sm
S
CK
Crr
max
0max0
sm
sss
CK
CrVFCFC
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Bioreactor Operation Modes3. Continuous stirred-tank reactor-Con.
ss
sms
CC
CrKC
0
max
F, Cs0
F, CsV
Mass balance of substrate:
0max0
sm
sss
CK
CrVFCFC
smss
s
CKCC
Cr
V
F
0
max
1
V
F
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1. Bioreactor configurations
2. Bioreactor operation modes
3. Practical considerations for bioreactor design
Outline of Lecture
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kcalYCVq
1
Heat production rate:
q : heat production rate, kcal/ls
V: reactor liquid volume, l
: specific growth rate, s-1
C: biomass concentration (g/l)
Ykcal: a yield coefficient given as grams of cells formed per kcal energy released, g cells/kcal
Heat load: Heat load is determined by energy balances
Practical Issues for Bioreactors- Temperature Control (Heat Load)
Popular method
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Practical Issues for Bioreactors-Temperature control (heat transfer)
Heat transfer surface area: 1. Low in (a) external jacket and (b) external coil for small reactors2. High in (c) internal helical coil and (d) internal baffle coil for large reactors3. Easily adjustable in (e) a separate external heat exchange unit
Difficult to cleanEasily fouled by cell
growth on the surface
No cleaning problem
• Sterility requirement
• Shear forces imposed on cells
• Depletion of oxygen
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1. Biological reactions almost invariably are three-phase reactions (gas-liquid-solid). Effective mass transfer between phases is often crucial. For example, for aerobic fermentation, the supply of oxygen is critical.
HPCgAA
* gAAlA CCKJ *
The equation governing the oxygen transfer rate is:
Agitation:
•Mechanical stirring (for small reactors, and/or viscous liquids, low reaction heat)
•Air-driven agitation (for large reactors and/or high reaction heat)
Practical Issues for Bioreactors-Agitation (gas transfer)
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1. Mechanical foam breaker (a supplementary impeller)
2. Chemical antifoam agents (may reduce the rate of oxygen transfer)
Practical Issues for Bioreactors- Foaming removal
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1. Aseptic operation (3-5% of fermentations in an industrial plant are lost due to failure of sterilization.
2. Construction materials (glass for small bioreactors, e.g., < 30 liters and corrosion-resistant stainless steel for large reactors)
3. Sparage design (three designs: porous, orifice and nozzle)
4. Evaporation control due to dry air input
Practical Issues for Bioreactors- Other issues
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Summary of Lecture
1. Bioreactor configurations
2. Bioreactor operation modes
3. Practical considerations for bioreactor design
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BIOREACTOR DESIGN
1. MIXING
2. HOLD UP
3. MASS TRANSFER
4. FOAM
5. HEAT TRANSFER
6. POWER CONSUMPTION
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THANK YOU