RANCANGAN ALAT BIOPROSES

TPE4211

WAHYUNANTO AGUNG NUGROHO YUSRON SUGIARTO

DOSEN PENGASUH:

Mahasiswa mempunyai kemampuan menterjemahkan dan memahami perancangan berbagai tipe bioreaktor meliputi bentuk bioreaktor, proses, kondisi operasi, dan susunan bioreaktor, serta pemilihan tipe bioreaktor

TUJUAN KULIAH

MATERI KULIAH No Pokok Bahasan Sub Pokok Bahasan Waktu

(Jam)

1 3 4 5

1. Pengantar Overview Bioreaktor 2 x 50

2. Tahap Inokulasi Dasar mikroorgmisme kurva pertumbuhan

2 x 50

3. Dasar pemodelan reaktor Modelling, matematis monod 2 x 50

4. Konfigurasi Bioreaktor Stirred Tank Bubble colomn

2 x 50

5. Konfigurasi Bioreaktor Airlift Reactor Stirred and Air Driven Reactor

2 x 50

6. Konfigurasi Bioreaktor Packed Bed Trickle Bed

2 x 50

7. Konstruksi Bioreaktor Aseptic Operation Fermenter inoculation and

sampling Materials of construction Sparger design Evaporation control

2 x 50

No Pokok Bahasan Sub Pokok Bahasan Waktu (Jam)

1 3 4 5

8. Monitoring and Control of Bioreactor (1)

Fermentation monitoring Measurement analysisi Fault analysis Process modelling State estimation

2 x 50

9. Monitoring and Control of Bioreactor (2)

Feed back control Programmed controlled Application of Artificial Intelegence in

Bioprocess control

2 x 50

10.

Ideal Reactor Operation Batch operation of a mixed reactor Enzyme reaction Cell culture, Chemostat with immobilised cells Chemostat with cell recycle Continues operation of a lug-flow reactor

2 x 50

11. Sterilisasi Batch heat sterilisation of liquids Continues heat sterilisation of liquids Filter sterilisation of Liquids Sterilisation of air

2 x 50

12. Peningkata Skala Bioreaktor Peningkata Skala Bioreaktor 2 x 50

13. Pengembangan reaktor baru (1) Pengembangan reaktor biogas, bioethanol 2 x 50

14. Pengembangan reaktor baru (2) Pengembangan reaktor baru biodiesel 2 x 50

MATERI KULIAH (2)

3 SKS (2-1) UTS : 30% UAS : 30% TUGAS (1) : 10% TUGAS (2) : 10% PRAKTIKUM : 20%

INTRODUCTION TO BIOREACTOR SYSTEM

What is BIOREACTOR?

What is the different between REACTOR and BIOREACTOR?

BIOREACTOR A reactor system/vessel used for the cultivation of an organism to produce the organism or a product, or in some specialized cases to carry out specific reactions. Main industrial equipment for fermentation process.

REACTOR reactors are vessels designed to contain chemical reactions. One example is a pressure reactor. The design of a chemical reactor deals with multiple aspects of chemical engineering. Chemical engineers design reactors to maximize net present value for the given reaction.

Major Function of Bioreactor To provide controlled environment for growth of microorganism (or mixture) to obtain desired product.

Other functions

of a Bioreactor 1. Provide operation free from contamination

2. Maintain a specific temperature

3. Provide adequate mixing and aeration

4. Control the pH of the culture

5. Allow monitoring and/or control of dissolved

oxygen

6. Allow feeding of nutrient solutions

7. Provide access points for inoculation and

sampling

8. Minimize liquid loss from the vessel

9. Facilitate the growth of a wide range of organisms

Points to be considered in designing and constructing bioreactor: 1. Microbiological and biochemical characteristics of cell systems. 2. hydrodynamic characteristics of the bioreactor. 3. Mass and heat characteristics of the bioreactor. 4. kinetic of cell growth and product formation. 5. Genetic stability characteristics of the cell system. 6. Aseptic equipment design. 7. Control of bioreactor environment (macro and

microenvironments). 8. Implication of bioreactor design on downstream product

separation. 9. Capital and operating costs of the bioreactor. 10. Potential for bioreactor scale up.

In any process, the bioreactor should not regarded as an isolated unit but as part of integrated process (include upstream and downstream processes)

strain isolation, storage, growth and preparation of inoccula as well as sterilization of the bioreactor and the medium.

involve the extraction and purification of the products. 20-60% of the total manufacturing costs

Upstream

Downstream

•pH •Temperature •DO (dissolved oxygen) •Air flow •Agitation

Basic elements for control of a bioreactor

Major components of an industrial bioreactor

Major components of an industrial bioreactor

Major components of an industrial bioreactor

Sterile medium is passed into the bioreactor at a steady flow rate, and culture broth emerges from it at the same rate, keeping the volume of the total culture in the bioreactor constant.

Diagram of a simple lab continuous fermentor

Optimization of production processes

1. Strain improvement (Classical and recombinant DNA methods) 2. Fermentation process optimization 3. Downstream process optimization

Vary in size and complexity, test tube (10 ml) to computer controlled fermenters (>100 m3).

Fermentor Scale Up

• Can not start cell culture in 100,000 L, must do repeated, scaled inoculations

• Start with stock culture (5-10 mL)

• Then shaker flask (200-500 mL)

• Then seed fermentor (10L to 100 L)

• Then production fermentor

(1000 L to 100,000 L)

Stages involved in a typical manufacturing-scale fermentation

1 L 10 L-50 L 5K-50K L

Shake Flask Incubator

Shake Flask Incubator

All Cells Can be Grown in Incubators or Fermenters

• Four basic bioreactor designs: – Stirred tank reactors (mechanical agitation

for aeration)

– Bubble column reactors (bubbling air into media for aeration)

– Internal loop airlift reactors (air and media circulate together)

– External loop airlift reactors

A: Stirred tank B: Bubble column C: Internal-loop airlift reactor D: External-loop airlift reactor

Four Bioreactor Designs

Main parts of a benchtop fermentor

1) Mechanical: drive motor, heater, pump, gas control

2) Vessel and accessories

3) Peripheral equipment such as reagent bottles

4) Instrumentation and sensors

3

2

4

1

Anatomy of a benchtop bioreactor

Lab Scale Fermentor

Industrial Scale Fermentor

Industrial Scale Fermentor

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