ANAlysis an<j. DEsiqN. BiOREACTORS. Education Private Limited TAPOBRATA PANDA. Professor of Biochemical Engineering, NEW DELHI. McGraw-Hill Offices

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1 BiOREACTORS ANAlysis an<j DEsiqN TAPOBRATA PANDA Professor of Biochemical Engineering, Indian Institute of Technology Madras, Chennai Tata McGraw Hill Education Private Limited NEW DELHI McGraw-Hill Offices New Delhi New York St Louis San Francisco Auckland Bogota Caracas Kuala Lumpur Lisbon London Madrid Mexico City Milan Montreal San Juan Santiago Singapore Sydney Tokyo Toronto

2 Contents Preface Acknowledgements vii ix 1. INTRODUCTION Overview of Biological Reactions Submerged liquidfermentation (SLF) Solid-state fermentation (SSF) Elements in Bioreactor Design Rate Expression in Biological Systems Enzymatic reactions Cellular reactions Basic Concept of Energy Metabolic energy 11 Transfer Factors affecting performance in bioreactors Effect ofagitation Effect of shear Effect of modes of heat transfer Basic Concept of Mass Balance 12 Exercises 12 References 13 Appendix 1 16 References to Appendix UNDERSTANDING OF BIOREACTORS What is a Bioreactor? Why Should We Study 2.3 Development 2.4 Purpose and Importance Bioreactors? 18 of Bioreactors Necessary functions of bioreactors a Requirementsfor bioreactor Major components and its purposes 24 of Bioreactors Additional information on important components 25

3 xii Contents 2.5 Other Bioreactor Configurations Bioreactor Development for Solid- State Fermentation (SSF) Necessary features of a typical bioreactor used in SSF Classification of Bioreactors Classification of bioreactors in SLF Classification of bioreactors in SSF Bioreactors for Animal Cell Cultivation Development of bioreactors Classification of bioreactors usedfor animal cell culture Bioreactors for Plant Cell Culture Reactors for suspension culture Bioreactors for Immobilized System Sterilization Bioreactors Bioreactors Used in Different Areas of Environmental Control and Management Bioreactors Used for Combined Reactions and Separation 80 Exercises 81 References 82 Further Reading BIOREACTOR OPERATION Introduction Common Operations of Bioreactor Setting up of bioreactor for submerged liquid fermentation (SLF) Inoculum development for bioreactor operation Selection/Identification of Other Common Factors Necessary for Smooth Operation of Bioreactors Spectrum of Basic Bioreactor Operations Experimental laboratory bioreactors Microbial free cells and cellular reactions in basic bioreactor Reactor Operation for Immobilized Systems Operation of Animal Cell Bioreactors Methods of preparation of culture of animal cells Sources of contamination Safety precautions for animal cell cultures Basic precautions Batch reactor operation Continuous flow (CHEMOSTAT) culture operation Perfusion culture operation Operation of hollow fiber bioreactor for hybridoma culture 140

4 Contents xiii 3.7 Operation of Bioreactors for Plant Cell Culture Reactors for Waste Management 144 Exercises 144 References 146 Appendix BIOCHEMICAL ASPECT OF BIOREACTOR DESIGN Introduction Organization of this Chapter General groxoth reaction Rate laws Temperature dependence of rate laiv for growth Stoichiometry Application of yield factors The mass balance General energy balance in bioreactors 158 SECTION A: BIOREACTORS FOR SUBMERGED LIQUID FERMENTATION OF MICROBIAL CELLS 160 Part 1: Batch Bioreactors Introduction Calculation of total batch time Calculation of batch reaction time from ideal system Calculation of trfor simultaneous synthesis ofcells and products Non-ideality in batch bioreactor Quantitative evaluation of batch processes 187 SECTION A: BIOREACTORS FOR SUBMERGED LIQUID FERMENTATION OF MICROBIAL CELLS 190 Part 2: Continuous Flow Bioreactors Introduction Purpose of continuous flow reactors Differences between turbidostat and chemostat operations Ideal CFSTBR-Chemostat Application of single stage CFSTBR Rate of output of cell mass in a chemostat Mean residence time (x) Comparison of batch bioreactor and single stage CFSTBR Washout condition Plug Flow Tubular Reactor (PFTR) Comparison of ideal mixedflow (batch and CFSTBR) and plug flow tubular reactors 211

5 Some xiv Contents 4.6 Recycle Bioreactors Objectives Recycling in biological reactions Analysis of recycle reactors 214 SECTION A: BIOREACTORS FOR SUBMERGED FERMENTATION OF MICROBIAL CELLS Part 3: Combination of Bioreactors Combination of Bioreactors Combination of continuous flow bioreactors Classification ofmultistage bioreactors Analysis of CFSTBRs in series with single stream SECTION A: BIOREACTORS FOR SUBMERGED LIQUID FERMENTATION OF MICROBIAL CELLS 232 Part 4: Semi-Contimwus Bioreactors Semi-continuous Bioreactors Afew definitions Analysis of semi-batch reactor Fed-batch bioreactors 237 SECTION B: BIOREACTORS FOR ENZYME REACTIONS AND IMMOBILIZED CELLS Introduction Input to Kinetic Modeling of Enzyme Ideal reactors 241 Reactors Analysis of ideal enzyme reactors: Substrate inhibition Analysis of ideal enzyme reactors: Product inhibition Steps for enzyme reactor design Immobilized enzyme reactions 250 Example Problems 256 Exercises 258 References ANALYSIS OF NON-IDEAL BEHAVIOR IN BIOREACTORS Introduction Non-ideal Parameters In CFSTBR Residence Time Distribution Ways to characterize RTD 2?1 Aspects of Macro Mixing Some Exercise for RTD of Ideal Systems (Ideal Bioreactors) Moments of the Distribution 276

6 Contents xv 5.6 E(t) or F(t) and the Bioreactor Design How to identify non-idealities in the system? Assessment of non-ideality Models for Non-ideal Flow Single parameter models The purpose of the parameters Models for non-ideal tubular reactors Models for non-ideal CFSTBRs Multi Parameter Models Application of RTD Based Models to Non-Ideal Bioreactors Drawbacks of Classical RTD Measurements Macro-mixing Mixing time Micro mixing-another factor for non-ideality in the bioreactor Transient Behavior in Bioreactors Classification of continuous change in environmental factors Characterization of transient state Stability and dynamic behavior ofbioreactor Stability and eigen Examples 303 values Stability Analysis for Continuous Flow Bioreactor with Substrate Inhibition Phase Plane Analysis Generalized phase-plane behavior Development ofphase plane diagram for a bioreactor The Bifurcation Analysis Drawbacks of dynamic analysis What is bifurcation? Different terms used in bifurcation analysis pertaining to bioreactor analysis Types of local bifurcation 323 Exercises 325 References BIOREACTOR MODELING Model What is It? Use of models Classification of models Definition of Lumped and Distributed Parameter Models Introduction to a Few Terminologies and Theorems Modeling Principles Steps in Modeling 333

7 xvi Contents 6.6 Fundamental Laws Used in Process Modeling 6.7 First-Order Systems 6.8 Second-Order Systems 6.9 Complexity of the Model Parameter Sensitivity Exercises 345 References 346 Appendix TRANSPORT PROCESSES IN BIOREACTORS Introduction Mass transfer Mass transfer phenomena in bioreactors Heat Transfer 7.3 Other Parameters Influencing Transfer Operations Power input Mixing Exercises 362 References 363 time CONTROLS IN BIOREACTORS Introduction Multivariable systems Nonlinear dynamics Control Tasks in a Bioreactor System 8.3 Instrumentation to Control a Bioreactor Controlled Variables and Measurement Devices Procedure for Design of Efficient Control Systems Linear stability analysis Bifurcation analysis Conventional Control Techniques Examples of measurement and control by conventional techniques Advanced Control Techniques Adaptive control and online estimation Model predictive control (MPC) Artificial neural networks (ANN) Internal model control Feedback control Feed fonvard control Cascade or supervisory control

8 Contents xvii 8.8 Consistency Checks on Measurements Adaptive Online Optimizing Control of Bioreactor System Online optimization control for bioreactor Exercises 388 References 388 Appendix CASE STUDIES Introduction 9.2 Design of Packed Bed Bioreactor Design of a packed bed reactor for a bio-film growth on support system Specific design Design of packed bed bioreactor packed with immobilized whole cell catalysts Airlift Bioreactors Classification of airlift reactors Main design criterion Type of analysis What are the parameters to measure? Hollow Fiber Bioreactor (HFBR) Plant Cell Bioreactor Bioreactor considerations Classes of bioreactorsfor plant cell grozuth Design of bioreactor Design of Bioreactors for Solid State Fermentation (SSF) Mammalian Cell Bioreactor Design Fermentor balancing for semi-continuous multi-tank mammalian cell culture process 416 Exercises 417 References 419 Appendix APPLICATION OF COMPUTATIONAL FLUID DYNAMICS IN BIOREACTOR ANALYSIS AND DESIGN Introduction Modeling approaches Dimensionality of simulation Difference between Lagrangian and Eulerian approaches Fluid Dynamic Modeling Euler-Lagrange approach

9 xviii Contents Eulerian-Eulerian approach Model equations and averaging methods Hydrodynamic parameters Hydrodynamic model Turbulence modeling Simulation Computational domain Geometry grid generation Initial conditions Boundary conditions Evaluation 436 ofdesign parameters Exercises 437 References 437 Appendix SCALE-UP OF BIOREACTORS Introduction Additional Scale-Up Problems in Bioreactors Criteria of Scale-Up Single constant criteria Combination of criteria Similarity Criteria Scale-up based on constant power per unit volume Scale-up based on KLa Constant mixing time Scale-Up Methods Generalized Approaches to Scale-Up in Combination of Methods Hubbard method (1987) Method of Wang etal. (1979) Ettler's method (1992) Other methods Examples 460 Exercises 463 References MECHANICAL ASPECTS OF BIOREACTOR DESIGN Introduction Requirements for Construction of a Bioreactor Guidelines for Bioreactor Design Preferred materials for bioreactor design and fabrication Welding techniques 466

10 Contents xix 12.4 Bioreactor Vessels Geometry of reactor vessel Components in bioreactor vessel Size of the vessel The design procedure ofvessel wall ofbioreactor Design offlange Design ofshaft Design of pin key/sunk key Agitator Assembly Drive configuration Types of stirrer assembly Types of agitators 479 Exercises 484 References 484 Appendix Index 487

Contents. Preface XI Nomenclature XIII. Part I Basic Concepts and Principles 1

Contents. Preface XI Nomenclature XIII. Part I Basic Concepts and Principles 1 V Preface XI Nomenclature XIII Part I Basic Concepts and Principles 1 1 Introduction 3 1.1 Background and Scope 3 1.2 Dimensions and Units 4 1.3 Intensive and Extensive Properties 6 1.4 Equilibria and