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Lecture 16-17 - Bioreactor Design and Operation I and II

The document discusses different types of bioreactors used in fermentation processes. It describes solid state and submerged fermentation systems. It also discusses various operation modes of bioreactors like batch, continuous, and modified systems. The document outlines factors to consider in bioreactor design like oxygen supply, form of biocatalyst, and classification based on operation. It provides examples of different bioreactor types including stirred-tank, airlift, packed-bed, and immobilized cell reactors. Key considerations in bioreactor cultivation methods and design are also summarized.

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390 views37 pages

Lecture 16-17 - Bioreactor Design and Operation I and II

The document discusses different types of bioreactors used in fermentation processes. It describes solid state and submerged fermentation systems. It also discusses various operation modes of bioreactors like batch, continuous, and modified systems. The document outlines factors to consider in bioreactor design like oxygen supply, form of biocatalyst, and classification based on operation. It provides examples of different bioreactor types including stirred-tank, airlift, packed-bed, and immobilized cell reactors. Key considerations in bioreactor cultivation methods and design are also summarized.

Uploaded by

Lukas Red
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© © All Rights Reserved
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Bioreactros Design and opperation

Bioreactor Design I

-Overview of bioreactors

-Operation considerations

-Modified batch and continuous reactors (mass balance analysis)

Presentation Title | Date CRICOS code 00025B 2


Bioreactor Analysis and Operation
Fermentation processes

• solid state: water content:


40~ 80%, fermentation on
agriculture products and
food. E.g: rotary drum
fermentator

• submerged systems: water


content > 95%
e.g. bacteria, yeast.

Presentation Title | Date CRICOS code 00025B 3


Presentation Title | Date CRICOS code 00025B 4
- Classification:

operation modes:
- batch: stirred tank
- continuous: chemostat, fluidized-bed
- modified types of the above modes: fed-
batch, chemostat with recycle, multi-stage continuous reactors
Form of biocatalyst:
Oxygen supply:
- free cell (enzyme)
- aerobic: airlift
- immobilized cell (enzyme)
- anaerobic
packed-bed, membrane reactor

Presentation Title | Date CRICOS code 00025B 5


Industrial Bioreactor

Bioethanol plant with the capacity to produce 700 million liters of the biofuel
annually (Brazil)

Presentation Title | Date CRICOS code 00025B 6


Examples of Air lift bioreactors
(aerobic condition)
IMMOBILIZED CELL (ENZYME)
REACTOR

Advantages: (i) no risk of cell wash out, (ii) low contamination risk, (iii) protection of
cells from liquid shear.
Microbial, plant, or animal cells can be immobilized by attachment to
solid structures, usually a column matrix

Example: Yeast cells immobilized in calcium aginate


Requirements for Cultivation Methods

Biomass concentration which must remain high

Sterile conditions being maintained

Effective agitation so that the distribution of substances in the reaction is uniform

Heat removal (cooler)

Creation of the correct shear conditions - high may damage cells, low may lead
to flocculation or growth on wall and stirrer
Bioreactro design 2
Bioreactor design II
Stirred-tank bioreactors
Semi-continuous (Fed batch)
Along with the strengths of continuous bioreaction,
there are inherent disadvantages that may make this process unsuitable for
some types of bioreaction.
One challenge lies in controlling the production of
some non-growth-related products. For this reason, the
continuous process often requires feed-batch culturing,
and a continuous nutrient supply.
Fed-Batch
F, So

Nutrients are continuously or semi- Vo


continuously fed, while effluent is removed X,S,P
discontinuously.

overcome substrate inhibition or catabolite


repression by intermittent feeding of substrate by
maintaining low substrate concentration.
for production of secondary metabolites e.g.
antibiotics, lactic acid, E. Coli making proteins
from recombinant DNA technology.
Substrate limited fed-batch cultivation

DOT: dissolved oxygen transfer


After consumption of the initial substrate a continuous and constant feed of the
substrate is started.
More examples of stirred-tank bioreactors

(Bench-scale, glass)
Stirred-tank bioreactors

(Pilot scale, glass)


Stirred-tank bioreactors
(Commercial production scale; stainless steel)
Stirred-tank bioreactors
(Single-use stirred bag bioreactor; plastic vessel)

Ex: mammalian and insect cells


Stirred-tank bioreactors
Single-use ‘wave’ bioreactor (2L bag, plastic)

Insect cell culture is a common choice for heterologous protein


expression. Insect cells are able to express large quantities of protein with
complex post-translational modifications (Drosophila S2 cells)
Stirred-tank bioreactors
Single-use ‘wave’ bioreactor (500L bag, plastic)
Single-use bioreactors

Advantages and disadvantages

•single-use technologies reduces cleaning and


sterilization demands;
•Some estimates show cost savings of more than
60% with single use systems compared to fixed asset
stainless steel bioreactors;
•reduces the risk of cross contamination and
enhances the biological and process safety;
•scale up is limited compared to conventional
bioreactors
•Low oxygen transfer (stirrer speed is limited by the
delicate nature of the cells)
Stirred-tank bioreactors
Typical vessel design
Stirred-tank bioreactors
Typical bioreactor design ratios
Stirred-tank bioreactors
Vessel design – major design examples
Stirred-tank bioreactors
Vessel design – major design principles

Direct shell-side fluid flow along tube field. This increases the
effective heat transfer
Stirred-tank bioreactors
Vessel mixing
Mixing – Impeller design
Stirred-tank bioreactors
Mixing – Impeller design
Stirred-tank bioreactors
Mixing – Impeller design
Stirred-tank bioreactors
Mixing – Baffle design
Stirred-tank bioreactors
Mixing – Impeller and baffle design
Stirred-tank bioreactors
Mixing – Impeller and baffle design
Stirred-tank bioreactors
Microbial vs animal cell culture
Thank you
Dr Kim Peters | Senior Lecturer
School of Psychology
[email protected]
07 0000 000

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