Geometric volume of 1 fermenter=Working volume (WL)+

Calculate the dimensions of fermentor.

Height, Ht Dt HL Di Baffles
310310 3
(F)=
=11.1 KL
Flow Rate,
7200.3950.95
Dimensions
Geometric Volume = 479.394 KL = 479.39 m3 480 m3
Height of Tank(Ht) : Diameter of Tank (Dt )= 2:1
Ht = 2Dt

V= 2
480=

Dt3

3
2 Dt

Dt3 = 305.73
Dt = 6.73 7 m
Ht = 27=14 m
Dt 1
Diameter of Impeller ( Di = 3 = 3 =2.33 m=Di

I=

Dt 7
= =0.58 m 0.6
12 12

K=

Dt 7
= =0.14 m=K
50 50

80
(WL)=479.394 KL
100

Dw=

Di 2.33
=
=0.466 m 0.5 m
5
5

D b=

Di 2.33
=
=0.562 m 0.6 m=D b
4
4

Dd =

67
D=1.56 m=Dd
100

E=

Dt
=2.33m= E
3

4
D s= Di =1.864=2 m=D s
5

Ls =

19
D i =1.77 m=Ls
25

GL=

V=

Seed fermenter 10 of wL=

2
26.633+ 26.633=31.95 32
100

3
2 Dt

Dt3 = 20.371
Dt = 2.731m 3 m
Ht = 6 m
Di = 1 m
I = 0.25 m
K = 0.06 m
Dw = 0.2 m
Db = 0.25 m
Dd = 0.67 m

10
266.33=26.633
100

E= 1 m
Ds = 0.8 m
Ls = 0.76 m

Target = 3T/month = 36T/year

DSP Efficiency = 95%
Yield = 30.4 mg/g
Mass cell concentration = 13g/L
Time fermentation = 10 days
Calculation on monthly basis
The Lovastatin to be modulated in fermenters
x: amount of lovastatin

95% of x = 3T
95
x=3000
100

x=

3000100
=3157.894 Kg
95

30.4 mg Lovastatin in 1g cell biomass

3157.894 Kg

1g
3157.894 Kg
30.4103 g
3

103.8710 Kg . COW
1.3 g biomass 1 L
3

103.8710 Kg

1L
3
103.87 10 Kg
3
1.310 mg
= 7990000 L
= 7990 KL broth/ month
Total cycle time =

1 ( t p ) +10 ( t f )+ 1 ( t d )=12 day

Number of Batches per month=

Amount of broth per batch=

Number of fermenters=

30
=2.5batches /month
12

7990 KL
=3196 KL /batch
2.5

t p +t d +t f 1+10+1
=
=12 fermenter
td
1

WorkingVolume of 1 fermenter =

3196
=266.33 KL
12

Flow Rate = 11.1 KL/hr.

For 24 hours = 11.1 * 24 = 266.4 KL
Storage tank=266.4+

20
266.4
100

= 319.6 KL 320 KL
Number of storage tank = 2
Rotary Vacuum Filter = 20 KL/hr.
2 Vacuum Filter in parallel operation
40 KL/hr.
Time=

320
=8 hrs .
40

Extraction

Volume of Ethyl acetate=

600266.4
3
10
2

= 79.920 KL
80 KL
Total=266.4+ 80=346.4 KL
Number of Extractor = 1
Working Volume of Extractor = 346.4 347 KL
Extractor=347+

20
347=416.4 420 KL
100

Drying
Volume of Spray Drier = 20 KL/hr.
Number of Driers = 2
40 KL/hr.

Total after Extraction = 80 KL

Total=

80 KL
=2 hr .
KL
40
hr
g
266.495
l
0.395
=99.96 Kg
100

Volume after drying =

Diameter of disk of turbine, Dd

D d 67
=
Di 100

Dd =

67
67
D i=
1.18=0.7906 m=D d
100
100

Height from bottom of tank where 1st impeller is locate, E

E 1
=
Dt 3
1
1
E= D t= 3.54=1.18 m=E
3
3
Height of tank (Ht ) = 7 m
80% of Ht = 5.6 m
Number of impellers

5.6
=4 impellers
1.18

Diameter of the Sparger , Ds

Ds 4
=
Di 5

4
4
D s= Di = 1.18=0.944 m=D s
5
5

Height from bottom of tank where Sparger is locate, Ls

L s 19
=
Di 25

Ls =

19
19
Di = 1.18=0.8968 m=Ls
25
25

Number of fermenters=

Cost of 1
fermenter

2
2
=
=4
10.5 0.5

= KfVa

=12,025(70)0.5
= $ 10060.36
= .
60,36,502

Total cost of
fermenters

=
60,36,502*4
=Rs.
2,41,46,008

Amount of moisture that remains = 2%

Total amount =

99.962
99.96
100
= 101.95 Kg

Lactonization

5
Amount of Benzene required= 101.95=127.43 L
4
Amount of TFA required = 2.54 L
Volume of Drying=101.95+127.43+2.54

= 231.9 L
232 L

Spray drier = 250 L/hr.

Number of dryer = 1
Time = 1 hr.

Total Time
RUF
Extraction
Spray
Dryer
Lactonizat
ion
Spray
Dryer
Total

= 8 hr.
= 1 hr.
= 2 hr.
= 2 hr.
= 1 hr.
= 14
hr.

Dimensions of Extractor
Size = 420 KL = 420 m3
Height of Tank (Ht ) : Diameter of Tank (Dt ) = 2:1
Dt = 6.5 m
Ht = 13 m

Di 1
=
Dt 3

D i=

6.5
=2.166 m=Di
3

J
1
=
Dt 12

J=

6.5
=0.541 m=J
12

K 1
=
Dt 50

K=

6.5
=0.13 m=K
50

Dw 1
=
Di 5

Dw=

2.166
=0.43 m=D w
5

Db 1
=
Di 4

D b=

2.166
=0.54 m=D b
4

D d 67
=
Di 100

Dd =

67
2.166=1.45 m=Dd
100

E 1
=
Dt 3

E=

6.5
=2.166 m=E
3

Ht = 13 m
80% of Ht = 10.4
Number of impellers=

10.4
=4 impellers
2.166