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Bio Reactor Design Calculations

This document provides information for scaling up a fermentation process from a 15 L lab scale fermentor to an industrial scale fermentor with a working volume of 2.7 m^3. Key details include: - The desired industrial fermentor would have a diameter of 1.25 m and height of 3.75 m. - Scaling calculations determine the agitation rate should be 30 rpm and total power consumption would be approximately 9940 watts. - Calculations of the oxygen transfer rate result in a KLa value of 1.158 s-1, confirming the aeration rate of 2.7 m3/hr would be adequate for the larger scale.

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Dr Narayana Saibaba K.V.
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373 views

Bio Reactor Design Calculations

This document provides information for scaling up a fermentation process from a 15 L lab scale fermentor to an industrial scale fermentor with a working volume of 2.7 m^3. Key details include: - The desired industrial fermentor would have a diameter of 1.25 m and height of 3.75 m. - Scaling calculations determine the agitation rate should be 30 rpm and total power consumption would be approximately 9940 watts. - Calculations of the oxygen transfer rate result in a KLa value of 1.158 s-1, confirming the aeration rate of 2.7 m3/hr would be adequate for the larger scale.

Uploaded by

Dr Narayana Saibaba K.V.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
You are on page 1/ 6

Sheet1

Volume of fermentor 15 liters


Working volume of fermentor 9 liters

Total acid produced 125.04 gm/lit

Citric acid produced 119.6 gm/lit

Dry cell mass 13.5 gm/lit

Sugar consumed 92.5 gm/lit

Specific productivity 0.928 ?

Aeration rate 1 vvm

Agitation rate 200 rpm

Design goal Amount of citric acid per day 323 kg

Working volume of fermentor 2.700668896 M^3

Total volume of desired reactor 4.501114827 M^3

Reactor dimensions
assume height:diameter ratio 3:1 3 1
impeller diameter 0.45 times tank diameter

Lab scale fermentor volume = pi * d^2 * h 15000 Cm^3

Diameter of lab scale fermenter 18.533 cm

Ratio of volume of desired and lab scale fermenters 300.0743218 Vd/Vlab

Scale up factor (Vd/Vlab)^(1/3) 6.67

Diameter of desired fermenter 1.2361511 1.25 M^3

Height of desired fermenter 3.75 3.75 M^3

Diameter of impeller 0.5625 0.5625 m

Scale up based on constant impeller tip velocity


N1d1 = n2d2 labscale 3706.6 n1d1
n=rpm
d=impeller diameter n2=n1d1/d2 29.6528 30 rpm

Page 1
Sheet1
Power required for agitation
Power number PNO=P/(rho * N^3 *D^5)
PNO 1.2 for turbulent flow
rho 1200 density kg/m^3

power required P= P=PNO*(rho * N^3 *D^5) 32 watts


1.2*1200*(30/60)^3*(0.5625)^5

Power required for aeration


Pg=rhog * Fo * (RT/Mw) *( ln (p2/p1) + alpha*Uo^2/2 )
density of air rhog = 1.2 kg/m^3
Fo flow rate 2.7 M^3 units?
MW of air 29 units?
Temperature T 300 K
R 8.314 JM^-1 K^-1

outlet pressure p2 101325 Pa atm pressure


calc inlet pressure p1
pressure of medium=Hdg 26460 19110 Pa
minimum p1= 127785 Pa 1.261139896
p1 1.2
Use p1 to drive air 2
alpha 0.6 typical

calc Uo gas velocity at sparger orifice


Uo = volumetric flow rate / sparger hole area 3.669 Ms^-1

Pg= 1318.428932
calc power required for agitation Pg= 9908 watts

Total power consumed = Pg+P 9940 watts

Determination of Kla

Oxygen uptake rate (OUR) = q_O2 * X = Kla * (C* - C)


Respiration rate of cells 3 mmol/gm-dw of cells
X dry mass 13.5 gm/lit
C* saturation DO conc. 8 mg/lit
C req 70% of saturation value 0.7

16*3mmol/gm-dw *13.5gm/lit = kla * 8mg/lit (1.0 – 0.7)

calc Kla 270


303.4 per hour ?
0.084277778 per sec

Page 2
Sheet1
Kla expression based on power consumption
Kla=2 * 10^-3 * (P/V)^0.7 * Ugs^0.2 units=per sec
P/V power per unit volume
Ugs = superficial gas velocity = gas flow rate / ( vessel cross section area * gas holdup)

Ugs 0.366878981 Ms^-1


use holdup=0.1 0.1

calc Kla= 1.158 per sec hence air flow adequate

Page 3
Sheet1

this is 3*pi * d^3 volume is pi.r2h

Page 4
Sheet1

reynold number needs to calculate first

1 atm

atm
atm
atm

assume holes occupy 1% area of tank cross section pi*d^4/4

may be 32 in place of 16

Why

Page 5
Sheet1

a * gas holdup) may be gas holdup not required

hence air flow adequate ?

Page 6

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