Essential Data for Bioreactor Design: Scaling Up from Laboratory to Plant Operations
This chapter offers a comprehensive overview of the vital data needed for selecting and designing bioreactors at various scales. Key aspects include microorganism species, growth conditions, and operational factors such as shear, sterility, volumetric output, and more. It emphasizes the importance of scale-up techniques—ensuring that designs maintain similar effects of process variables across different sizes to yield consistent results. Essential stirred tank design principles and power consumption metrics are also discussed for successful commercial operation.
Essential Data for Bioreactor Design: Scaling Up from Laboratory to Plant Operations
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Presentation Transcript
CHAPTER 8 TRANSLATION OF LABORATORY, PILOT AND PLANT SCALE DATA
Data Required for Bioreactor Selection and Design • Microorganism species • Growth and oxygen requirements • Shear and rheology effects • Sterility • Volumetric output • Light • Foam • Final use • Cleaning and sterilizing • Heating and cooling • Materials of construction • Measurement Systems
Definition of Scale Up The successful startup and operation of a commercial size unit whose design and operating procedures are in part based upon experimentation and demonstration at a smaller scale.
The purpose of scale up is the selection design conditions and operational procedures to ensure that the effect of the different variables on the process is the same in units of different size. • Also to obtain similar yield
Scale up Procedure • Similar Reynolds number or momentum factors. • Constant power consumption per unit volume of liquid, Pg/V • Constant impeller tip velocity, Ndi 4. Equal mixing and recirculation time, tm 5. Constant mass transfer coefficient, Kla
Stirred Tank Design • Height:Diameter ratio between 2:1 to 6:1 • Fitted with baffles • 4 baffles if the tank diameter is less than 3 m • 6-8 baffles if the tank diameter larger than 3m • Width of baffles, T/10 and T/12
Constant Power per Unit Volume • P/V determines the Reynolds number value • NDi determines the maximum shear stress • When the fluid in the tank is full turbulent, the power number is constant • P N3Di5 • P/V N3Di2 • (N3Di2)1 = (N3Di2)2
