SPECIFICATION SHEET

IDENTIFICATION
Name of Equipment Fermenter
Equipment Code J-4
Type Stirred Bioreactor (Aerobic)
Mode of Operation Batch
Number of Units 8 units
Fermentation Time 36hours
Function To produce Glutamic Acid using
Corynebacterium Glutamicum
BASIC DESIGN DATA
Materials Handled Glucose, Water, Inoculum, Aqueous NH3
Density 1,037.73 kg/m3
Viscosity 1.22 x 10-3 kg/m3
Maximum Temperature 30
Pressure 1.00 atm
VESSEL DESIGN
Material of Construction SS316
Volume per unit 17 m3
Height 4.25 m
Diameter 2.4 m
Shell Thickness 6 mm
Head Thickness 6 mm
Bottom Thickness 6 mm
Head Type Ellipsoidal Head
Weld Type Single-butt welded joints
Welding Efficiency 0.6
IMPELLER DESIGN
Impeller Type Rushton Impeller (6-Disk flat blades)
Number of Impellers 3
Impeller Diameter 0.8 m
Impeller Height 0.16 m
Impeller Width 0.2 m
Impeller Clearance at the Bottom 0.8 m
Number of Baffles 4
Width of Baffles 0.234 m
Distance between Impellers 1.2 m
Speed of Rotation 42.67 rpm
Power Requirement 2 hp
 HEATING SYSTEM DESIGN
Area of Jacket 6 m2
Height of Jacket 2m
Diameter of Jacket 5m
Material of Construction SS 316
Thickness of Jacket 7 mm
Heating Medium Hot Water
Heating Temperature 80
ILLUSTRATION:
II. LIST OF ASSUMPTIONS

1. Batch aerobic fermenter will be used in the fermentation process.

2. SS316 will be the material of construction to be used in vessel design.

3. Height of liquid to Diameter of the tank ratio is 1.5 for stability purposes.

4. 20% of the total volume of feed is allotted as an allowance for vapor space.

5. Impeller type that will be used is six-blade disk

6. API-ASME vessel design code will be used.

7. Motor efficiency of the agitator is around 80%

8. Assume maximum time for charge feed to the reactor, heat to reaction temp, and empty

and clean reactor time.

III. DESIGN EQUATIONS

1.75 C6H12O6 + 1.35 O2 + 2NH3+ C5H9NO4 + C4.5H8O2.2N + CO2 + 5H2O

Kinetics of Reaction

Growth Rate of Bacteria

(Ref: Lee, James E. (2009) Biochemical Engineering)

=
+

Where:

= specific growth rate, h-1

max = maximum specific growth rate, h-1

CS = substrate concentration, g/L

KS = Monod constant, g/L

= yield coefficient of biomass,

= residence time,

max= 0.21

Ks = 0.8
Vessel Design

Volume of Vessel

VT = 1.2 VFEED

Vessel Diameter and Height (Ref: Fermentation Processes Engineering in the Food

Industry)

ratio = 1 2

Internal Pressure (P)

P = Patm + Hliquid

Working Stress, Sw

Sw =

SW (for SS 316) = 128,900 kPa = 18,695.36 psi

(Ref: ASME vessel design from Peters and Timmerhaus, Table 12-10 p. 555)

Shell Thickness

(Ref: ASME vessel design from cylindrical shell from Peter and Timmerhaus, Table 12-10 p.

554)

= +
0.6

Limiting conditions:

0.385
2

Head Thickness

(Ref: ASME vessel design from ellipsoidal head from Peter and Timmerhaus, Table 12-10 p.

554)

= +
2 0.20

Limiting conditions:

t 0.356 or P 0.665S

Impeller Design

Details of Geometric ratios of fermenters with three (six-blades) impellers.

(Ref: Pressure Design Vessel Manual, pp. 329 and Lee, James E. (2009) Biochemical

Engineering)

Impeller Diameter
1
Dimpeller = 3 Dvessel

Impeller Height
1
Dimpeller = 3 Dvessel

Impeller Width

Width = 0.25Dimpeller

Impeller Blade Height

Height = 0.2 Dimpeller

Baffle Width
1
Width = 10Dvessel

Distance of the First Impeller from the Vessel floor

1
Distance = 3 Dvessel

Distance between Impeller

Distance = 1.5 Dimpeller

 Viscosity Determination(Ref: Estimation of viscosity of highly viscous fermentation

media containing one or more solutes, p.82)

= ( ) + ()

Where:

AW = 2.41 x 10-3

BW = 1774.9 K

2
AG = 8.65 x 10-10

BG = 2,502.0 K

CG = Glucose concentration, 3

T = Fermenter temperature, K

Power Requirement (Ref: Unit Operations of Chemical Engineering by McCabe and

Smith 6th edition, p.256-260)

2
Re =

P = kL n23 or P = kT n35

Agitation Scale-up

(Ref: Liquid Mixing and Processing in Stirred Tanks by Chapman et.al)

2
2 = 1 ( )3

Heating System Design

= ( )

= 4 (2 2 ) ( )
Where:

S.G.Steel = 7.83 (Ref: ChE Handbook 8th edition, Table 2-120)

CpSteel = 0.12 cal/g- = 0.50 kJ/kg K(Ref: ChE Handbook 8th edition, Table 2-176)

Tfinal = 30, steady-state operating temperature

Tinitial = 26, initial steel temperature

Total heat needed: Basis: 1 unit

QTotal = +

QUnit =

Area of Jacket

Where:

(Th TCin )(TCout Thout )

in
TLM = (Th TC )
in in
ln
(TC Th )
out out

Heat Transfer Coefficient for Jacketed Vessel

(Ref: Table 7.6 p.386 Chemical Process Engg. Design Economics by Silla)

U = 428.632
 Amount of Hot Water Needed

=

Volume of Hot Water Handled by Jacket per unit

VHOT WATER PER UNIT=

Diameter of Jacket

AJ= = (2
2
)
4

Height of Jacket

4Vfeed per unit

Hjacket =
D2jacket

Thickness of Jacket

= +
0.6

Where:

EJ = 0.60, single-butt welded joints

Cc = 1/8 in, corrosion allowance

IV. DETAILED DESIGN COMPUTATIONS

VESSEL DESIGN

From Material Balance

COMPONENT Mass (kg) Density Flow Rate (m3)

Glucose 12,542.05 1,540 8.14

Maltose 1,368.52 1,540 0.89

Water 115,077.45 1,000 115.08

Alpha-amylase 7.73 1,250 0.006

Protein 582.39 1,350 0.431

Fats 211.84 896.3601 0.24

Glucoamylase 4.51 1,892.6 0.0024

Pullulanase 3.87 1,250 0.003

Inoculum 2,650.14 1,000 2.65

NH3 1,138.2 880 1.29

TOTAL 133,586.7 128.73

Average Density

133,586.7
=
128.73 3

= 1,037.73 3 = 64.78 3
Kinetics of Reaction:

=
+

(Ref: Modeling the Growth of Corynebacterium Glutamicum in L-Glutamic Acid Fermentation)

0.21
max =

Ks = 0.8

12,542.05
Cs = = = 97.43
128.73 3

0.21

97.43 .
= =
0.8 +97.43

Reaction Rate

(Ref: Eq. 7-153, ChE Handbook, 8thed)

Reaction:

1.75 C6H12O6 + 1.35 O2 + 2NH3+ C5H9NO4 + C4.5H8O2.2N + CO2 + 5H2O

= 0.2113

= 0.70
Cx = 0.47 g/L (Biomass Concentration)

= =

0.7 0.2083 0.47

=( )( )( )
0.2113

= reaction rate = 0.32

Calculated Residence Time

,
= = (Ref: Lee, James E. (2009) Biochemical Engineering)

Where:

Csi = concentration of glucose for cell mass growth (g/L)

ri = reaction rate (g/ L-hr)

Csi = 11.27 g/L

Solving for :

11.27 /
= = = 35.22 hr 36 hrs
0.32

Batch Process:

Fermentation time (tR) = 36hrs

(Ref: Chemical Process Engineering Design and Economics by Silla)

Activity Time (hr)

Charge Feed to the Reactor (tF) 1.5 - 3

Heat to reaction temp (tH) 1-2

Empty and clean reactor (tE) 0.5-1

1 batch (tB) = tR + tF + tH + tE

1 batch (tB) = 36hr + 3 hr + 2 hr + 1 hr

1 batch (tB) = 42hr

Volumetric Flow Rate of the Feed:

Volume of the Feed: 128.73 m3

0.2083 3
F = V = (128.73 m3) = 26.81

Vessel Capacity

Vfeed = 128.73 m3129 m3= 4,543 ft3

Vtank = 1.2Vfeed = 1.2 (128.73m3)

Vtank = 154.48 m3155 m3 = 5,452 ft3

1000
Vtank = 154.48 m3 x = 154,480L
13
From Brochure:

Volume = 19,800 L

Diameter =2.4 m

Height = 4.25 m

154,480
Number of Units = = 7.80 units 8 units
19,800

Vessel Diameter and Height

1 1
Vfeed per unit = 128.73 m3 x 1 x = 16.09 m317 m3 = 568 ft3
8

1 1
Vtank per unit = 154.48m3 x 1 x = 19.32 m3 20 m3 = 682 ft3
8

Hliquid = 1.5 Dtank

Hliquid = 1.5 (2.4 m) = 3.6 m 4 m = 11.81 ft 12 ft

Htank = 4.25 m = 14 ft

Maximum Allowable Internal Pressure

P = Patm + Hliquid

1 2 32.2
2
P = 14.7 psi + (64.78 3 ) (11.81 ft x 2
)( )
144 32.2 2

P = 20 psi (1.36atm)
MATERIAL SPECIFICATION

Material of Construction: SS316 (Ref: Microbial fermentative processes, biomass, enzymes,

amino acids, http://biomikro.vscht.cz)

Maximum Allowable Working Stress

SW (for SS 316) = 128,900 kPa = 18,695.36 psi

(Ref: ASME vessel design from Peters and Timmerhaus, Table 12-10 p. 555)

SHELL THICKNESS

= +
0.6

Where:

EJ = 0.60, single-butt welded joints

2.4 = 1.2 m = 47.23 in

rI = 2= 2

Cc = 1/8 in, corrosion allowance(Ref: Plant Design and Economics for Chemical

Engineers, 4th ed.)

(20 )(47.23 ) 1
= (18,695.36 + in
)(0.60)0.6(20 ) 8

t = 0.21 in = 5.33 mm 6 mm

45.28
Limiting conditions, ; 0.202
2 2
HEAD THICKNESS

= +
2 0.20

Limiting conditions:

t 0.356 or P 0.665S

Where:

EJ = 0.60, single-butt welded joints

Cc = 1/8 in, corrosion allowance

= +
2 0.20

(20 )(94.88 ) 1
= + in
2(18,695.36 )(0.60)0.2(20 ) 8

t = 0.21 in = 5.33 mm 6 mm

BOTTOM THICKNESS

tB= th = 0.21 in = 6 mm

IMPELLER DESIGN

Details of Geometric ratios of fermenters with three (six-blades) impellers.

(Ref: Pressure Design Vessel Manual, pp. 329 and Lee, James E. (2009) Biochemical

Engineering)

Impeller Diameter
1 1
Dimpeller = 3Dvessel= (2.4 m) = 0.8 m
3
 Impeller Height

Himpeller= 0.2 Dimpeller

1
Dimpeller = 3 Dvessel

Himpeller = 0.2 (0.8 ) = 0.16 m

Impeller Width

Width = 0.25Dimpeller

Width = 0.25 (0.8 m) = 0.2 m

Impeller Blade Height

Height = 0.2 Dimpeller

Height = 0.2 (0.8 m) = 0.16 m

Baffle Width
1
Width = 10Dvessel

1
Width = 10 (2.4 m) = 0.24 m

Distance of the First Impeller from the Vessel floor

1
Distance = 3 Dvessel

1
Distance = 3(2.4 m) = 0.8 m

Distance between Impeller

Distance = 1.5 Dimpeller

Distance = 1.5 (0.8 m) = 1.2 m

Viscosity Determination (Ref: Estimation of viscosity of highly viscous fermentation

media containing one or more solutes, p.82)

= ( ) + ()
Where:

AW = 2.41 x 10-3

BW = 1774.9 K

2
AG = 8.65 x 10-10

BG = 2,502.0 K

CG = Glucose concentration, 3

T = Fermenter temperature, K
1774.9
( ) 2,502
= (2.41 x 10-3 ) 28+273 + (97,427 )(8.65 x 1010 )
3 2 28+273

1
= 1.22 x 1000 = 1.22 x 10-3

Power Requirement (Ref: Unit Operations of Chemical Engineering by McCabe and

Smith 6th edition, p.256-260)

2
Re =

(180 )(1 60 ) (0.8)2 (1,037.73 )
3
Re =
1.22103

Re = 1.63 x 106turbulent

2
2 = 1 ( )3

(Ref: Liquid Mixing and Processing in Stirred Tanks by Chapman et.al)

0.277 2
2 = (180 )( )3
2.4

2 = 42.67 rpm
In baffled tanks and if NRe> 10,000, then Np = KT

(Ref: Unit Operations of Chemical Engineering by McCabe and Smith 6th edition, p.256-260)
3
P = KT n35 = 5.75 [(42.67 )(160)] (0.8)5 (1,037.73 3 )

P = 703.26 W = 0.94 hp

Motor efficiency, = 80% (Ref: Agitator Power, www.checalc.com)

703.26
Pactual = =
0.80

Pactual = 879.08 W = 1.18 hp = 2 hp

HEATING SYSTEM DESIGN

Heat Transfer Rate

From Energy Balance;

= -44,353,165.82 kJ

Consider: Amount of heat absorb by the vessel wall

= ( )

= 4 (2 2 ) ( )

Where:

Di = 2.4 m

Do = 2.412 m

Hv = 4.25 m
 S.G.Steel = 7.83 (Ref: ChE Handbook 8th edition, Table 2-120)

CpSteel = 0.12 cal/g- = 0.50 kJ/kg K(Ref: ChE Handbook 8th edition, Table 2-176)

Tfinal = 30, steady-state operating temperature

Tinitial = 26, initial steel temperature

= 4 ((2.412)2 (2.4)2 )(4.25 ) (7.83 1000 3) (0.50
)(30 26)

= 3,018.40kJ

Total heat needed: Basis: 1 unit

QTotal = +

QTotal = -44,353,165.82 + 3,018.40 kJ= -44,356,184.22 kJ

1000 J
QT 44,356,184.22 kJ x
1 kJ
QUnit = = 3600 s = -42,781.81 J/s = -42,781.81 W
Fermentation Time 8 units (36 hrs) x
1 hr

Feed Temperature Hot Water Temperature

Inlet, Tcin Outlet, Tcout Inlet, Thin Outlet, Thout

25 30 80 27.5

(Thin TCin ) (Thout Tcout ) (80 25) (30 27.5)

TLM = (Th TC )
= (8025)
ln (T in T in ) ln (3027.5)
hout cout

TLM = 16.98 = 290.13K

Heat Transfer Coefficient for Jacketed Vessel

(Ref: Table 7.6 p.386 Chemical Process Engg. Design Economics by Silla)

U = 428.632

Q |42,781.81 W|
Aj = =
UTLM (428.63 W )(16.98)
m2 K

AJ = 5.88m2 62

Amount of Hot Water Needed

3600 42
|42.78| ( )( 1 )
1
= =
4.184 (300.65 353.15 )

= 29,447.04 kg 29,448 kg/unit

Volume of Hot Water Handled by Jacket per unit

3
VHOT WATER PER UNIT= 29,448 x
1,000

29.45 3
VHOT WATER PER UNIT=

Diameter of Jacket

AJ= = (2
2
)
4

3
29.45 2
= ( 2.4122 )
3.6 4

Djacket = 4.03 m 5m
 Height of Jacket

4Vfeed per unit 4(16.09 3 )

Hjacket = = = 1.26 m2 m
D2jacket (4.03 )2

Thickness of Jacket

= +
0.6

Where:

EJ = 0.60, single-butt welded joints

12.04
rI = 2= 2 = 6.02 ft = 72.23 in

Cc = 1/8 in, corrosion allowance

(20 )(72.23 ) 1
= (18,695.36 + in
)(0.60)0.6(20 ) 8

t = 0.25 in = 6.45 mm 7 mm