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Chapter 9 VNL
(2 lectures)
Gas inlet
V = liquid volume
Contents
• How to design a process?
• Reactor types
• Characteristics of processes
• Microbial (”fermentation”)
• Mammalian
• Algal
• Waste water treatment
• The Stirred Tank Reactor
• Batch /Continuous operation/Fed-batch
• Some design cases
• Fed-batch (Example 9.7)
• Recirculation (Example 9.3)
• Multiple reactors (Example 9.2)
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Designing the process
When we (believe that we) have our production organism and we know
(certain aspects) of the kinetics of the process, we can start the design of
our process. There are two fundamental questions:
• What are the best conditions?
• i.e. what substrate concentration(s), T, pH etc should we have..
• How do we obtain the best conditions?
• What reactor type is most suitable?
• Stirred tank reactor, airlift, plug flow reactor, reactors in series,
recirculation reactors..
• What mode of operation is best?
• Batch, fed-batch, continuous operation.. (from a kinetic point of
view? From a practical point of view? From an economic point of
view?)
High yield
• We want as much as possible of our substrate to be converted into our sellable (our
most highly priced) product. A high yield is crucial for any bulk product where the
substrate cost is the dominating large fraction of the OPEX (operating costs) .
High titer (concentration)
• A major part of OPEX in almost any bioprocess are the downstream cost (i.e. the costs
for separation & purification). These costs are normally product concentration
dependent.
High productivity
• If CAPEX (capital costs, i.e costs for equipment/factory) are high, it may be more
important to produce more product per time and reactor than to achieve a high yield.
2
Reactor types
bed with e.g.
immobilized aeration
cells
medium
inlet
draft
stirrer tube
sparger aeration
sparger
pump
a b c d e
Stirred tank Column type reactors
Lab-scale bioreactor
Steel reactor (10 – 20L)
Cell culture – lab scale
3
Air-lift reactors
For the really big scale
Figure 9.17 Probably the largest air lift reactor ever constructed with a volume of
1900 m3 and a height of 60 m. The reactor was commissioned around 1970 and
used for production of SCP from methanol by the ICI company at Billingham, UK
4
Plug flow (packed bed) reactors
For immobilized systems
J. N. Warnock et al, Packed Bed Bioreactors, in Bioreactors for Tissue Engineering, Eds. Chaudhuri and El-
Rubeai, Springer, Dordrecht, 2005
Encapsulation
Surface attachment
(biofilm)
Hollow fiber
Entrapment
AnoxKaldnes biocarriers
5
Forced loop bioreactor
A hybrid reactor
Microbial bioprocesses
6
Mammalian cell cultures – it is all
about mAbs!
*Other hosts could be cell lines of human origin, such as the HeLa cell line (named after the cancer
patient Henrietta Lacks from 1951) or BHK – baby hamster kidney cells
7
Reactors for Mammalian cell cultures
Flat bed photobioreactor advertised on India mart Tubular photobioreactor from bbi biotech
8
Mode of operation
f , cf
Inflow
e , ce
Outflow
V, c
d (Vc)
V (q t q) v f c f ve c e Note: A system of ODEs
dt
Volumetric transfer rate Volumetric production rate
(gaseous compounds)
9
Considering only the liquid phase
Batch Continuous Fed-batch
(no inflow, no outflow of (inflow and outflow of liquid) (inflow but no outflow of
liquid) liquid)
, cf , cf
, c
at ss
dc dc v
q(c) 0 q(c) (c f c)
dc
q(c)
v(t )
(c f c)
dt dt V dt V (t )
Batch
Two (or more) coupled ODEs Simplest case - Monod
Monod kinetics
100
Substrate & biomass concentrations
60
dx
x ; x(t 0) x0
40
dt 20
ds
Yxs x ; s(t 0) s 0 0
dt
-20
0 2 4 6 8 10 12 14 16 18 20
Time (h)
Note: This is not a lag phase max = 0.5 h-1, Ks = 0.1 g L-1
A lag phase can only be seen in a plot of log x vs time
10
Batch
Batch processes are simple, but (typically) have a
low average productivity
Final productivity
Monod kinetics
100
Substrate & biomass concentrations
40 Decay of biomass?
20
-20
0 2 4 6 8 10 12 14 16 18 20
Time (h)
Continuous cultivation
How do the concentrations change with time?
Biomass
Steady-state operation
? Long term stability?
Start-up
time
No change in concentration with time!
11
Continuous cultivation at SS
Concentrations vs D for a simple Monod case
Monod kinetics
120
s
q x x max x Dx
Concentration (g/L)
s Ks 100
80
max s DK s
Ds 60 Biomass
Ks s max D
40
max s f 20
Prerequisite: D Substrate
Ks s f 0
0 0.1 0.2 0.3 0.4 0.5 0.6
D (1/h)
If this is not fulfilled, wash-out occurs max = 0.5 h-1, Ks = 0.1 g L-1
wash-out
The yield coefficients are constant, and for a reasonable affinity for the substrate, the
obtained concentrations are almost unchanged for a wide range of dilution rates.
Continuous cultivation at SS
Productivity (xD) vs D
30
20
Maximum
10
-10
0 0.1 0.2 0.3 0.4 0.5 0.6
D (1/h)
12
What is the exact value of D at optimum conditions?
d ( Dx )
We have that 0
dD
Somewhat algebraically easier is to find the optimal substrate concentration, sopt
s
d max YSX ( s f s)
K s
0 s 0
d ( Dx )
ds ds
s 2 2K s s K s s f 0 s opt K s K s2 K s s f
𝑚𝑎𝑥 𝑠𝑜𝑝𝑡
𝐷𝑜𝑝𝑡 =
𝐾𝑠 + 𝑠𝑜𝑝𝑡
𝑠
𝑆= ”Dimensionless concentration”
𝑠𝑓 S
m a S
𝐾𝑠 ”Dimensionless affinity”
𝑎=
𝑠𝑓
1
Since 0 SFor
1Swe
< 1get i.e. if a is small m as S 1
m a 1
S
max YSX d (1 S )
using S and a, we get: aS 0
dS
S 2 2aS a 0 Sopt a a 2 a
13
Continuous cultivation
Example 9.1 Monod kinetics with maintenance
(the ”Herbert experiment”)
The stoichiometry of the main (“true”) reaction is obtained using the procedure in Chapter 3:
CH8/3O + 0.4483 O2 + 0.1368 NH3 → 0.6842 CH1.8O0.5N0.2 + 0.3158 CO2 + 0.923 H2O (1)
x (biomass)
s (glycerol)
14
Whether or not the change in yield coefficient is positive
depends entirely on the process!
Example 9.1
Ysp (g CO2/g glycerol)
m s
A typical kinetic expression is 2
in this case s Ks s
Ki
Or in dimensionless form
S a
Ks sf
2 where b
m bS S a sf Ki
a
It is easily shown that has a maximum for S opt
b
15
Chemostat with substrate inhibition
Sopt < 1, i.e. sopt < sf Sopt > 1, i.e. sopt > sf
/m /m
1 S 1 S
16
Fed-batch
Most fed-batch processes are started with a batch phase
x
Often xf =0 (no biomass in feed,
only substrate) ?
For biomass, we thus get
d (Vx ) dx 1 dV
Vx x x
dt dt V dt
dx
( ) x
dt V t
Batch Fed-batch
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The origin of fed-batch
Bakers’ yeast production
• Long time ago in Egypt
• Distributed small scale production (keeping of inoculum)
• Middle ages
• Surplus yeast obtained from breweries
• About 1860 Drawing by Turpin from 1840
• Dedicated process for production (Vienna process) –
aeration introduced
• WW I
• Change of substrate (from grain to molasses)
• 1919
• Fed-batch (Soren Sak process)
• By controlling the specific growth rate, aerobic ethanol
formation (overflow metabolism) was avoided
Overflow metabolism
A B
Glucose Glucose
Low specific glucose uptake rate – respiratory metabolism
CO2 CO2
18
E. coli - Overfeeding may result in either
overflow metabolism or oxygen limitation
Pyruvate
NADH
NADH
Acetyl-CoA PEP Fumarate Succinate
TCA-
NADH
Acetyl-P cycle
Pyruvate Lactate
ATP
Acetate
Formate CO2 + H2
Acetyl-CoA
NADH
Acetyl-P
Acetaldehyde
ATP NADH
Acetate
Ethanol
Ri qi ( z (u (t ), x)) dV
V
19
The ”normal” fed-batch control problem
Feed rate
Overflow
metabolism
Allowed
operational range
q s VX 0 e t Time
F t
S in S t
Optimal (extremum) control
Fed-batch
20
Fed-batch control
Control Modelling
Measurement
Substrate tank
Reactor
Fed-batch control
• Empirical optimization
• Simply try and see what happens for different feed
profiles. If it works – use that feed profile! (still not
uncommon in industry..)
• Physiologically motivated feed-back controls
• Find information on the physiological status of the
culture, e.g. by probing control
• Model-based optimization
• Base your control on a kinetic (and reactor) model. This control
can be open loop or closed loop
21
”Probing control”
CER (mmol h )
-1
(I)
Gas Analyzer
10
Feed 5
0
0 0.1 0.2 0.3 0.4 0.5
Time (h)
”Probing control”
No response!
DOT (%)
DOT (%)
30 30
10 10
0 4
0 4
Flow rate
Flow rate
0 4 time
0 4 time
(min)
(min)
22
Plug flow reactor
The PFR requires that the inflow contains biomass (or that biomass is retained)
The PFR is therefore used primarily for immobilized systems, but may also be
used as a final ”polishing” reactor in a reactor system
dx S
x
S
V
dV s f xS0 q S
, sf
s (s ds) qS dV 0
ds 𝑠
qS 𝑉
=න
𝑑𝑠
dV 𝑠𝑓 𝑞𝑠
Capacity comparisons
ds qs (s)dV 0
V s f sout sf
V ds
qs (s)
so u t
qs ( s )
V 1
D
23
1
For a first order reaction, qs
we qualitatively get
Tank
-qs
sout sf s
1
qs
s
i.e. for a first order
reaction, the PFR is to be PFR
prefered (since the
colored area is smaller) sout sf s
12
10
s opt K s K s2 K s s f 2.31
8 Integral VPFR
-1/qs (g/L h)
0
1 2 3 4 5 6 7 8 9 10
s (g/L)
24
Finding the optimal value for s (and D) for maximizing
biomass productivit
20 20
15 15
Substrate
inhibition
10 10
maintenance
10 10
Product
5 5
inhibition
0 0
0.0 0.2 0.4 0.6 0.8 1.0 0.0 0.2 0.4 0.6 0.8 1.0
S S
• Fed-batch
• Baker’s yeast production
• Recirculation
• Waste water treatment
• Multiple reactors
• Waste water treatment
25
Fed-batch design for Baker’s yeast production
The critical specific growth rate above which overflow metabolism is about 0.25 h-1 ,
i.e. the feed rate should be controlled so that s = 250 mg L -1
26
Fed-batch design for Baker’s yeast production
So, how do we actually feed so that we avoid overflow metabolism (i.e. keep s < 250 mg /L)?
We could have a glucose sensor on-line and apply a PID controller (perhaps).
Alternatively we use a simple feed forward design based on the mass balance
equation.
The fed-batch operation is likely to start after a batch phase, which ends at a relatively
low biomass concentration, say 1 g/L.
We could try to set the feed rate to 0.25*V (i.e. a "dilution rate" of 0.25 h-1, which is
the desired value of
Eventually, the feed rate will approach 0.25*V (when x approaches Ysx(sf-scrit).
However, starting with that rate will not be good.
Huge overfeeding!
27
Fed-batch design for Baker’s yeast production
If the initial concentration of s at the start of the fed-batch is the desired, it is easy to
decide on a strategy. We can set 𝑉𝑥𝑌𝑥𝑠
= 𝑐𝑟𝑖𝑡 ൘(𝑠 − 𝑠 )
𝑓 𝑐𝑟𝑖𝑡
x V
V x
For a given value of kl a we can determine the maximum biomass concentration for
our feed strategy.
Assume that kl a = 650 h-1 (which is possible in a stirred reactor - but not in the type
of reactor used ), we get
xmax = 142.5 10-3 /( 0.684* 0.25) = 0.833 C-mol L-1 = 20.47 g L-1.
28
Waste water treatment (Example 9.3)
A hypothetical waste water stream treated in a CSTR
𝑚 = 1 ℎ−1
sf = 4 g L-1 𝑚 𝑠
= 𝐾𝑠 = 1 𝑔 𝐿−1
𝐾𝑠 + 𝑠
=1 m3 h -1
𝑌𝑠𝑥 = 0.5 𝑔 𝑔−1
V = 0.5 m3
Wash-out! No removal of s at all! 𝐷= = 2 ℎ−1
𝑉
sf = 4 g L-1
What is the best choice of 1?
= 1 m3 h -1
1
(partly cleaned)
V = 0.5 m3
2
(uncleaned)
𝑠𝑜𝑝𝑡 = −𝐾𝑠 + 𝐾𝑠2 + 𝐾𝑠 𝑠𝑓 = 1.23 𝑔 𝐿-1 Dopt = 0.552 h-1
1 = 0.552*0.5=0.276 m3 h-1
The BEST you can do is thus to let 73.4 % of the waste simply by-pass the CSTR
29
What if you do not want to do that?
Then you will need a different design– one possibility is cell
recirculation
Same volumetric flow rate into and out of system
Centrifuge/or other
v, sf v(R+1) separation method
x, s, p v xe, s, p
Alternative configurations
30
Centrifuge/or other
v, sf v(R+1) separation method
Recirculation
x, s, p v xe, s, p
x
xe s Biomass in reactor
xe s
end
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