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Bioreactor - Types and Functions

The document provides an overview of bioprocess technology, focusing on various types of bioreactors including Continuous Stirred Tank, Tubular Tower, Air Lift, Bubble Column, Packed Bed, and Fluidized Bed reactors. Each type is described in terms of its design, mechanism, advantages, disadvantages, and applications in industries such as pharmaceuticals, environmental biotechnology, and agriculture. The information highlights the importance of bioreactors in optimizing conditions for microbial growth and product formation.
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0% found this document useful (0 votes)
531 views72 pages

Bioreactor - Types and Functions

The document provides an overview of bioprocess technology, focusing on various types of bioreactors including Continuous Stirred Tank, Tubular Tower, Air Lift, Bubble Column, Packed Bed, and Fluidized Bed reactors. Each type is described in terms of its design, mechanism, advantages, disadvantages, and applications in industries such as pharmaceuticals, environmental biotechnology, and agriculture. The information highlights the importance of bioreactors in optimizing conditions for microbial growth and product formation.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Bioprocess Technology

Bioreactor – Types &


Functions

Dr D Jayasheela
Associate Professor
Department of Biotechnology
Sri Ramakrishna College of Arts &
What is a Bioreactor?
 An apparatus (usually jacketed cylindrical SS
vessel) for growing organisms such as bacteria,
viruses, or yeast that are used in the production of
pharmaceuticals, antibodies, or vaccines, or for the
bioconversion of organic wastes.

 Under optimum conditions of gas (air, oxygen,


nitrogen, and carbon dioxide) flow rates,
temperature, pH, dissolved oxygen level, and
agitation speed, the microorganisms or cells will
reproduce at a rapid rate.
What is a Bioreactor?
Bioreactor/ Fermenter
Designs
1.Continuous Stirred Tank
2.Tubular tower
3.Air lift reactors
4.Bubble Column
5.Packed bed reactors
6.Fluidized bed reactors
Continuous Stirred tank
 reactor
The Continuous Stirred Tank bioreactor is the
classical design and still the most widely
used bioreactor.
 Most production facilities and FDA approved
production processes for biopharmaceuticals
are based on the stirred tank bioreactors.
 The scale-up process from laboratory to
production sized systems is therefore based
on this design as well.
 This cylindrical bioreactor uses a top or
bottom mounted rotating mixing system.
Continuous Stirred tank
reactor
 In Continuous Stirred Tank Bioreactor, the contents
of the vessel no longer vary with time, this applies to
the hold up of micro-organisms and the
concentration of the components of the medium in
the fermentor.

 Steady state conditions can be achieved by either


Chemo static or Turbid static principles which is
used to control the flow rate.

 Both these methods have been employed in


practice though the former is obviously the simpler
from every view point.
Continuous Stirred tank
reactor
Features
• Microbial reactors have impellers to provide
agitation and generally have baffles from the walls
to prevent vortexing of the fluid.
• High mechanical stress in the stirrer shaft, bearings
and seal.
• Bioreactors for animal cell cultures usually do not
have baffles (to reduce turbulence).
• The aspect ratio (height-to-diameter ratio) of the
vessel is 3-5 for microbial cultures but is normally
less than 2 for animal cell culture.
• Sparger: gas is sparged at the bottom using a
perforated pipe ring sparger.
• Different types of impellers (Rustom disc, concave
bladed, marine propeller etc.) are in use.
Mechanism
• In stirred tank bioreactors, the air is added to the
culture medium under pressure through a device called
sparger.
• The sparger may be a ring with many holes or a tube
with a single orifice.
• The sparger along with impellers (agitators) enables
better gas distribution system throughout the vessel.
• The bubbles generated by sparger are broken down to
smaller ones by impellers and dispersed throughout the
medium.
• This enables the creation of a uniform and
homogeneous environment throughout the bioreactor,
which enables the bioprocess reaction to efficiently
perform.
•The bioprocess endures the desired product through
Continuous Stirred tank reactor
Continuous Stirred tank reactor
Continuous Stirred tank reactor
Continuous Stirred tank reactor
Continuous Stirred tank reactor
Advantages
• Continuous operation
• Good temperature control
• Easily adapts to two phase runs
• Good control over parameters and environment
• Simplicity of construction
• Flexible and Low operating (labor) cost and
investment needs
• Easy to clean
• Can cope up with high concentrations due to
superior heat transfer
• Efficient gas transferto growing cells and
mixing of the contents
Disadvantages
 The need for shaft seals and bearings.
 Size limitation by motor size, shaft length
and weight.
 Foaming is often a problem.
 Consumption of power is more due to the
mechanical pressure pumps.
Applications
 The most successful continuous systems to date
have been those employing yeasts and bacteria,
in which the desired products are the cells.
 Production of primary metabolites,
enzymes and amino acids.
 The production of alcohol (product clearly
associated with growth or energy producing
mechanisms).
 The most widely used is the activated sludge
process used in waste water treatment industry.
Tubular Tower reactor
 An elongated non mechanically stirred
fermenter having the aspect ratio 6:1 for
tubular section and 10:1 for overall ,
through which there is a unidirectional
flow of gases.
 Simple tower fermenter are those with
are sparger at the base used for citric
acid production.
 Humid sterile air was supplied through
the base.
Tubular Tower reactor
 These fermenters were designed for beer
production and to maximise yeast biomass
yields.
 A series of perforated plates are placed at
intervals to maximise yeast yields. It has a
settling zone free of gas.
 In this zone, yeast cells settle down to the
bottom and return to the main body of the
tower fermenter, and clear beer could be
removed from the fermenter.
 Tower of up to 20,000 / capacity and
capable of producing up to 90,000 I beer
per day have been installed.
Tubular Tower reactor
In these fermenters, a column forms the
body of vessel, which is divided into
compartments by placing perforated plates
across the fermenter.

 About 10% of the horizontal area of


plates perforated.

 These fermenters have been used for


continuous culture of E.coli , S.cerevisiae
(yeast) and activated sludge.
Tubular Tower reactor
Tubular Tower reactor
Tubular Tower reactor
Tubular Tower reactor
Tubular Tower reactor
Applications
FERMENTATION BIOTECHNOLOGY
Dairy industries - curd / yogurt, butter, cheese
Alcohol based industries – beer / wine, toddy, vinegar.

ENVIROMENTAL BIOTECHNOLOGY
Water and waste water treatment Bioremediation
Solid waste management industries composting biogas.

AGRICULTURAL BIOTECHNOLOGY
Biofertilizers
Biopesticides

PHARMACEUTICALS INDUSTRIES
Antibiotics
Steroids
Vaccines
Probiotics
Food supplements
Air lift reactor

Definition
• Air-lift bioreactors are similar to bubble column
reactors, but differ by the fact that they contain a
draft tube.

• The draft tube is always an inner tube (this type of


air-lift bioreactor is called “air-lift bioreactor with an
internal loop”) or an external tube (called “air-lift
bioreactor with an external loop”), which improves
circulation and oxygen transfer and equalizes shear
forces in the reactor.
• Internal-loop airlift bioreactor has a single container with a
central draft tube that creates interior liquid circulation
channels. These bioreactors are simple in design, with volume
and circulation at a fixed rate for fermentation.

• External loop airlift bioreactor possesses an external loop so


that the liquid circulates through separate independent
channels.

• These reactors can be suitably modified to suit the


requirements of different fermentations.

• In general, the airlift bioreactors are more efficient than


bubble columns, particularly for more denser suspensions of
microorganisms.

• This is mainly because in these bioreactors, the mixing of the


contents is better compared to bubble columns.
Air lift reactors
Mixing method:
airlift
• Central draft tube
• Up-flowing
stream and
down flowing
stream
• Homogenization
of all
components
present
• Applications
includebacterial,
Features
1. Separated as two zones: the sparged zone is called
the riser, and the zone that receives no gas is the
downcomer.
2. The bulk density in the riser region is lower than
that in the downcomer region, causing the
circulation (so circulation is enhanced if there is
little or no gas in the downcomer).
3. For optimal mass transfer, the riser to downcomer
cross- sectional area ratio should be between 1.8
and 4.3.
4. The rate of liquid circulation increases with the
square root of the height of the airlift device.
Consequently, the reactors are designed with high
aspect ratios.
5. A gas-liquid separator in the head-zone can reduce
Mechanism
 In general, the performance of the airlift
bioreactors is dependent on the pumping
(injection) of air and the liquid circulation.

 It is different from the Stirred tank


bioreactor that needs the heat coat or
plate surrounding the tank to make warm
bioreactor. It is clear enough that the
Airlift bioreactor has greater heat-removal
compare to Stirred tank.
 Two-stage airlift bioreactors are used for
the temperature dependent formation of
products.
 Growing cells from one bioreactor (maintained at
temperature 30°C) are pumped into another
bioreactor (at temperature 42°C).
 There is a necessity for the two-stage airlift
bioreactor, since it is very difficult to raise the
temperature quickly from 30°C to 42°C in the
same vessel.
 Each one of the bioreactors is fitted with valves
and they are connected by a transfer tube and
pump.
 The cells are grown in the first bioreactor and
the bioprocess proper takes place in the
second reactor.
Air lift reactors
Air lift reactors
Air lift reactors
Air lift reactors
Advantages
1. Highly energy efficient and productivities
are comparable to those of stirred tank
bioreactors.
2. Simple design with no moving parts or agitator for
less maintenance, less risk of defects.
3. Easier sterilization (no agitator shaft parts)
4. Low Energy requirement vs. stirred tank
Obviously doesn’t need the energy for the
moving parts (agitator shaft).
5. Greater heat-removal vs. stirred tank
At the Airlift bioreactor it doesn’t need the heat
plate to control the temperature, because the
Draught-Tube which is inside the bioreactor can be
designed to serve as internal heat exchanger.
Disadvantages
 Greater air throughput and higher pressures
needed.

 The agitation on the Airlift bioreactor is controlled


by the supply air to adjust the supply air then the
higher pressure needed.

 the higher pressure of air needed then more


energy consumption needed and more cost must
pay.

 Inefficient break the foam when foaming occurs

 No bubbles breaker, There are no blades that


Applications
 The reactor is commonly used in the culture of
shear sensitive organisms.

 Airlift bioreactors are commonly employed


for aerobic bioprocessing technology. They
ensure a controlled liquid flow in a recycle
system by pumping.

 Due to high efficiency, airlift bioreactors are


sometimes preferred e.g., methanol production,
waste water treatment, single-cell protein
production.
Bubble column reactor

 Bubble column bioreactors are tall column


bioreactors where gas is introduced in the
bottom section for mixing and aeration
purposes.

 The vessel used for bubble column


bioreactors is usually cylindrical with an
aspect ratio of
4 - 6.
Bubble column reactor
Mixing method:
Gas sparging
• Simple design
• Good heat and
mass transfer
rates
• Low energy input
• Gas-liquid mass transfer
coefficients depend
largely on bubble
diameter and gas hold-
up
Features
 Usually the height-to-diameter ratio is 4 - 6.

 Gas is sparged at the base through perforated


pipes or plates or metal porous spargers.

 O2 transfer, mixing and other performance


factors are influenced mainly by gas flow rate
and rheological properties of the fluid.

 Mixing and mass transfer can be improved by


placing perforated plates or vertical baffles in the
vessel.

 Does not have a draft tube.


Mechanism
 In the bubble column bioreactor, the air or gas is
introduced at the base of the column through
perforated pipes or plates, or metal micro porous
spargers and causes a turbulent stream to enable
gas exchange.

 The flow rate of the air/gas influences the


performance factors —O2 transfer, mixing.

 The bubble column bioreactors may be fitted with


perforated plates to improve performance.

 The reactants are compacted in the presence of


finely dispersed catalyst and thus produce the
products using fermentation method.
Bubble column reactor
Bubble column reactor
Bubble column reactor
Bubble column reactor
Advantages
• Have high volumetric productivity and excellent
heat management.
• Better utilization of the plate area and
flow distrubution.
• Self regulating.

Disadvantages
• Less efficient than other bioreactors
• Does not have draft tube
• Higher catalyst consumption than the fixed bed
• Higher installation cost and difficult to design
Applications
 The reactor is commonly used in the culture
of shear sensitive organisms. E.g.: mould
and plant cells

 Productions of chemicals and


pharmaceuticals.

 Also for fermentation processes.


Packed bed reactor
• A bed of solid particles, with biocatalysts on or
within the matrix of solids, packed in a column
constitutes a packed bed bioreactor.
• The solids used may be porous or non- porous
gels, and they may be compressible or rigid in
nature.
• A nutrient broth flows continuously over the
immobilized biocatalyst.
• The products obtained in the packed bed
bioreactor are released into the fluid and removed.
• While the flow of the fluid can be upward or
downward, down flow under gravity is preferred.
The concentration of the nutrients (and
therefore the products formed) can be
increased by increasing the flow rate of the
nutrient broth.
Because of poor mixing, it is rather difficult
to control the pH of packed bed bioreactors
by the addition of acid or alkali.
However, these bioreactors are preferred
for bioprocessing technology involving
product-inhibited reactions.
The packed bed bioreactors do not allow
accumulation of the products to any
significant extent.
Packed bed reactor
• Column with
attached
biofilm
• Biocatalysts
• Pump is required
to make fluid
move through
the packed bed
• Applications
include waste
water
treatment
Features
• A bed of particles are confined in the reactor. The
biocatalyst (or cell) is immobilized on the solids
which may be rigid or macroporous particles.

• A fluid containing nutrients flows through the bed


to provide the needs of the immobilized
biocatalyst. Metabolites and products are released
into the fluid and removed in the outflow.

• The flow can be upward or downward. If upward


fluid is used, the velocity can not exceed the
minimum fluidization velocity.
Packed bed reactor
Packed bed reactor
Packed bed reactor
Advantages
 Higher conversion per unit mass of catalyst
than other catalytic reactors
 Low operating cost
 Continuous operation
 No moving parts to wear out
 Catalyst stays in the reactor
 Reaction mixture/catalyst separation is easy
 Design is simple
 Effective at high temperatures and pressures
Disadvantages
 Undesired heat gradients
 Poor temperature control
 Difficult to clean
 Difficult to replace catalyst
 Undesirable side reactions
Applications
• These are used with immobilized or
particulate biocatalysts.

• High conservation per weight of catalyst


than other catalytic reactors. Thus
mostly preferred fermentor.

• Used is waste water treatment.


Fluidized bed reactor

• Fluidized bed bioreactor is comparable to bubble


column bioreactor except the top position is
expanded to reduce the velocity of the fluid.

• The design of the fluidized bioreactors (expanded


top and narrow reaction column) is such that the
solids are retained in the reactor while the liquid
flows out.

• These bioreactors are suitable for use to carry out


reactions involving fluid suspended biocatalysts such
as immobilized enzymes, immobilized cells, and
microbial flocks.
• This is a characteristic of beds of regular
particles suspended in an up flowing liquid
stream.
• If an additional gas phase is involved, there is a
tendency for the particles in the bed to become less
evenly distributed.
• The fermentor consists of a vertical cylinder with an
aspect ratio is 10:1.
• At the top of the tower a separator is provided to induce
the gas bubbles produced by the reaction, to coalesce
and escape from the liquid phase.
• There are two important features of the beds of
mixed particle sizes:
• The increase in porosity from the bottom to the top of
the bed, and
• The decreased particle movement when compared
with beds containing particles of constant size.
Fluidized bed reactor
• When the
packed beds are
operated in up-
flow
mode, the bed
expands at
high liquid
flow rates due
to upward
motion of the
particles.
• Energy is
required
• Waste
Features
• Suitable for reactions involving a
fluid-suspended particulate biocatalyst such as
immobilized enzyme and cell particles.
• Similar to the bubble column reactor except that
the top section is expanded to reduce the
superficial velocity of the fluidizing liquid to a level
below that needed to keep the solids in suspension.
• Consequently, the solids sediment in the expanded
zone and drop back, hence the solids are retained
in the reactor whereas the liquid flows out.
• The properties include:
• Extremely high surface area contact between fluid and solid
per unit bed volume
• High relative velocities between the fluid and the dispersed
solid phase.
• High levels of intermixing of the particulate phase.
Mechanism

• For an efficient operation of fluidized beds, gas is


spared to create a suitable gas-liquid-solid fluid bed.

• It is also necessary to ensure that the suspended solid


particles are not too light or too dense (too light ones
may float whereas to dense ones may settle at the
bottom), and they are in a good suspended state.

• Recycling of the liquid is important to maintain


continuous contact between the reaction contents and
biocatalysts. This enable good efficiency of
bioprocessing.
Fluidized bed reactor
Fluidized bed reactor
Fluidized bed reactor
Advantages
 Uniform Particle Mixing
 Uniform Temperature Gradients
 Ability to Operate Reactor in Continuous
State
Disadvantages
 Increased Reactor Vessel Size
 Pumping Requirements and Pressure Drop
 Particle Entrainment
 Lack of Current Understanding
 Erosion of Internal Components
 Pressure Loss Scenarios
Applications
• These reactors can utilize high density of
particles and reduce bulk fluid density.

• Fluidized beds are used as a technical process


which has the ability to promote high levels of
contact between gases and solids.

• In a fluidized bed a characteristic set of basic


properties can be utilized, indispensable to
modern process and chemical engineering

• The food processing industry: fluidized beds are


used to accelerate freezing in some
individually quick frozen (IQF) tunnel freezers.

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