Types of reaction process

Types of reaction process:

chemical synthesis: Examples of synthetic
conversions include aspirin, diazepam, ibuprofen.
biotechnology or microbial action: Examples
include antibiotics, vaccine production, blood
plasma products. This method produces the high
value products;
extraction: This can be by extraction of natural
materials from animal or plant material such as
the opium alkaloids, dioxin, heparin, insulin (pigs
pancreas), thyroxine (animal thyroid gland).
 Synthetic chemistry based processes
include
 simple liquid/liquid reactions,
 complex liquid reactions
with catalysis such as Grinards, Freidel Craft,
reaction with strong reagents such as phosphorous
oxychloride, thionyl chloride or elemental halogens such as
bromine or chlorine.
Conventional batch reactor systems temp -25°C to +
1600C, and full vacuum to 6barg
The medium used for heating & cooling
 multiple fluids steam, cooling water, refrigerant fluids
heated or cooled by indirect
single fluids heat transfer oil-
contact with steam, cooling water or refrigerant
Alternative reactor systems
Alkylation

Phenobarbital, barbital…
Carboxylation and acetylation

salicylic acid and derivatives, acetaminophen

Condensation and Cyclization

Diazepam, riboflavin, vitamin B1…

Dehydration

Ether
Halogenation

Chloroform
Oxidation
isoniazid, nicotinic acid …
Sulfonation
sulfanilamide…
Amination
propanolol
Complex chemical conversions
Vitamin C, Darvon…
 Biotechnology based processes
 Process involved
 fermentation,
 Recovery,
 purification.
 Fermenters 
 (a) Open tank,
 (b) Stirred tank,
 (c) Gas-lift and
 (d) sparged-tank fermenters.
 Important design considerations for good fermenter
operation (a) Aeration and agitation,
 (b)PH,
 c) Sterile design,
 d) Temperature control,
 (e) Media sterilization
 Biotechnology based processes

Recovery and purification

(a) Large-scale extracellular products,
(b) Recombinant products,
(a) Cell disruption,
(b) Centrifugation,
(c) Ultrafiltration,
(d) Electrodialysis,
(e) Chromatography
 Biotechnology based processes
Process involved
 fermentation,
 Recovery,
 purification.
Fermenters 
 (a) Open tank,
 (b) Stirred tank,
 (c) Gas-lift and
 (d) sparged-tank fermenters.
Fermenters/bioreactors
Stirred tank bioreactors
Bioreactor Configurations
- 1. Stirred tank
Mixing method: Mechanical
agitation
•Baffles are usually used to
reduce vortexing
• Applications: free and
immobilized enzyme reactions
•High shear forces may
damage cells
•Require high energy input
Gas-lift
ggG
Bioreactor Configurations
- 3. Airlift reactor

Mixing method: airlift

• Compared to bubble
column reactors, in an
airlift reactors, there
are two liquid steams:
up-flowing and down-
flowing steams. Liquid
circulates in an airlift
reactor as a resutl of
density difference
between riser and
downcomer.
Bioreactor Configurations
- 4. Packed-bed reactor

Packed-bed
reactors are used
with immobilized
or particulate
biocatalysts.

Medium can be
fed either at the
top or bottom and
forms a
continuous liquid
phase.
 Bioreactor Configurations
- 2. Bubble column (sparged-tank fermenters)
Mixing method: Gas
sparging
• Simple design
•Good heat and mass
transfer
•Low energy input

Gas-liquid mass transfer

coefficients depend largely
on bubble diameter and gas
hold-up.
Bioreactor Configurations
- 6. Fluidized bed reactor

When the packed beds

are operated in upflow
mode, the bed expands
at high liquid flow rates
due to upward motion
of the particles.