Distributed stirring system for high-density microbial fermentation
By setting up vertically layered stirring units and sensor control systems in the bio-fermentation tank, dynamic stirring adjustment based on the metabolic state of microorganisms is achieved, solving the dissolved oxygen gradient problem caused by traditional stirring devices and improving the fermentation effect.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- LEYUN (NANTONG) ELECTROMECHANICAL MIXING EQUIP CO LTD
- Filing Date
- 2025-06-10
- Publication Date
- 2026-06-23
AI Technical Summary
The existing stirring devices in bioreactors cannot be dynamically adjusted according to the metabolic state of microorganisms, resulting in dissolved oxygen and nutrient gradients, which affect the fermentation effect.
It adopts a three-layer vertically distributed stirring unit, with each layer of stirring unit independently controlled. Combined with sensors and controllers to monitor the data inside the tank in real time, the stirring speed between different layers can be adjusted. It is equipped with a magnetic levitation stirring device and aeration function.
It improves the uniformity of mixing and fermentation efficiency in the fermenter, reduces the dissolved oxygen gradient, and enhances the stability and efficiency of high-density microbial fermentation.
Smart Images
Figure CN224394860U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of bioreactor equipment technology, specifically a distributed stirring system for high-density microbial fermentation suitable for high-density cultivation of microorganisms such as Escherichia coli and yeast. Background Technology
[0002] To ensure effective fermentation, bio-fermentation tanks typically incorporate a rubber rod device within the vessel. This device, along with a stirring mechanism, rapidly disperses air bubbles and mixes the added materials. Traditional bio-fermentation tanks often feature rudimentary stirring mechanisms, typically consisting of a single stirring shaft and multiple sets of impellers. For example: Figure 2 The structure shown has a single shaft driving the agitator to rotate or stop together, which can easily lead to dissolved oxygen / nutrient gradients in the tank. For example, the dissolved oxygen at the top may be 30% lower than that at the bottom. Existing agitation devices cannot dynamically adjust the agitation strategy according to the state of microbial metabolism, such as ethanol accumulation or the Crabtree effect, thus affecting the fermentation growth effect. Utility Model Content
[0003] The purpose of this invention is to provide a distributed stirring system for high-density microbial fermentation, in order to solve one or more of the problems mentioned in the background art.
[0004] To achieve the above objectives, this utility model discloses a distributed stirring system for high-density microbial fermentation. The distributed stirring system is installed on the body of a fermenter and includes at least three vertically layered stirring units, each layer comprising at least one stirring device. This structural design enables layered stirring within the fermenter, facilitating the rotation and stirring of different layers at the same or different speeds using the same or different stirring devices.
[0005] In some embodiments, the distributed stirring system for high-density microbial fermentation further includes a controller and a sensor group, wherein the sensor group and the power mechanism corresponding to the stirring device are both connected to the controller.
[0006] The sensor group includes several sensors, which are correspondingly arranged with the stirring unit. The sensor group is used to detect and acquire data inside the tank in real time. The data inside the tank includes one or more of dissolved oxygen, cell density, metabolic waste gas concentration and fluid shear force, wherein the metabolic waste gas concentration includes one or more of carbon dioxide concentration, ethanol concentration and acetic acid concentration.
[0007] The controller is used to acquire data from inside the tank and control the operation of each stirring unit based on that data.
[0008] In some implementations...
[0009] Each stirring device in the distributed stirring system is equipped with a power mechanism, which drives the corresponding stirring device to rotate, thereby achieving independent control of different stirring devices.
[0010] Different stirring devices within the same stirring unit may have the same or different structures; stirring devices within different stirring units may have the same or different mechanisms.
[0011] In some embodiments, the stirring device is a magnetic levitation stirring device. Using a magnetic levitation stirring device facilitates the disassembly and assembly of the stirring components inside the tank, which helps to keep the tank clean.
[0012] In some implementations...
[0013] The bottom stirring unit in the distributed stirring system for high-density microbial fermentation is a bottom stirring unit. The bottom stirring unit includes a stirring device, which is located in the middle of the bottom of the fermentation tank. An aeration device is correspondingly installed on the stirring device to form an aeration stirring device, which can better introduce the gas required for fermentation from the bottom of the tank as needed.
[0014] The topmost stirring unit in the distributed stirring system for high-density microbial fermentation is the top stirring unit.
[0015] The mixing unit located between the top mixing unit and the bottom mixing unit is the middle mixing unit. The mixing devices in both the middle mixing unit and the top mixing unit are located on the side wall of the tank, and the mixing devices in the middle mixing unit are inclined.
[0016] In some implementations...
[0017] The diameter of the agitator blade in the bottom agitator unit is 0.25-0.35 times the diameter of the fermentation tank.
[0018] The top of the tank is equipped with a defoamer replenishment device;
[0019] The stirring device of the intermediate stirring unit supports both forward and reverse rotation, and the tilt angle of the stirring device of the intermediate stirring unit is 45-60°.
[0020] In some embodiments, the sensor array includes a distributed light DO probe, a cell density detection module based on near-infrared and ultrasonic dual modes, and a gas mass spectrometer.
[0021] In some implementations...
[0022] The accuracy of the distributed optical fiber DO probe is ±0.05 mg / L;
[0023] The bacterial cell density detection module based on near-infrared and ultrasonic dual modes has an error of less than 3% and can monitor bacterial cell density online.
[0024] The gas mass spectrometer is used to detect headspace gas inside the fermenter and monitor the concentration of metabolic waste gas online.
[0025] In some embodiments, the power mechanism corresponding to the stirring device is an electric motor, and the distributed stirring system for high-density microbial fermentation also includes:
[0026] Torque limiter, which is installed correspondingly to the stirring device, to provide overload protection for the stirring device;
[0027] The power ripple acquisition device is connected to the power mechanism to acquire the ripple current value corresponding to the power mechanism. This value can be sent to intelligent devices through controllers, which can help detect problems such as feeding blockage and blade scaling.
[0028] Compared with the prior art, the beneficial effects of this utility model are: through the innovative design of the distributed stirring system for high-density microbial fermentation, regional stirring within the fermenter is achieved, which significantly improves the efficiency and stability of high-density fermentation. Attached Figure Description
[0029] Figure 1 This is a schematic diagram of the structure of a distributed stirring system for high-density microbial fermentation in some embodiments of this utility model;
[0030] Figure 2 This is a schematic diagram of the stirring device on a traditional bio-fermentation tank. Detailed Implementation
[0031] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0032] This invention discloses a distributed stirring system for high-density microbial fermentation. The distributed stirring system is installed on the body of a fermenter and includes at least three vertically layered stirring units, each layer comprising at least one stirring device. This structural design enables layered stirring within the fermenter, facilitating the rotation and stirring of different layers at the same or different speeds using the same or different stirring devices.
[0033] The distributed stirring system for high-density microbial fermentation may also include a controller and a sensor group. The sensor group and the corresponding power mechanism for the stirring unit are connected to the controller. The sensor group is configured to correspond to the stirring unit, and includes several sensors. The sensor group is used to detect and acquire data inside the tank in real time. This data includes one or more of dissolved oxygen, cell density, metabolic waste gas concentration, and fluid shear force. The metabolic waste gas concentration includes one or more of carbon dioxide, ethanol, and acetic acid concentrations. The controller acquires the data inside the tank and controls the operation of the corresponding stirring unit based on this data. The process of the controller controlling the operation of the corresponding stirring unit based on the data inside the tank can be implemented using existing PLC programs. The data inside the tank and the parameters of the stirring unit during operation (such as rotation speed) can be set in the program as needed. The sensor group described herein may include a distributed optical density (DO) probe, a cell density detection module based on near-infrared and ultrasonic dual-modality, and a gas mass spectrometer. The distributed fiber optic DO probe has an accuracy of ±0.05 mg / L; the cell density detection module based on near-infrared and ultrasonic dual modes has an error of less than 3% and can monitor cell density online; the gas mass spectrometer can be set on the top of the tank to detect headspace gas in the fermenter and monitor the concentration of metabolic waste gas online.
[0034] Each stirring device in the above-mentioned distributed stirring system is equipped with a power mechanism, which drives the corresponding stirring device to rotate, thereby realizing independent control of different stirring devices.
[0035] The structures of different stirring devices within the same stirring unit may be the same or different; the mechanisms of stirring devices within different stirring units may be the same or different.
[0036] All of the above-mentioned stirring devices can be magnetic levitation stirring devices. Using magnetic levitation stirring devices makes it easier to disassemble and assemble the stirring components inside the tank, which helps to keep the tank clean.
[0037] The bottom stirring unit in the above-mentioned distributed stirring system for high-density microbial fermentation is a bottom stirring unit. The bottom stirring unit includes a stirring device, which is located in the middle of the bottom of the fermenter. A corresponding aeration device can be added to the stirring device to form an aeration stirring device.
[0038] In a distributed stirring system for high-density microbial fermentation, the stirring unit located at the top is called the top stirring unit.
[0039] The mixing unit located between the top mixing unit and the bottom mixing unit is the middle mixing unit. The mixing devices in both the middle mixing unit and the top mixing unit are located on the side wall of the tank, and the mixing devices in the middle mixing unit are set at an angle.
[0040] The diameter of the agitator blade in the bottom agitator unit can be 0.25-0.35 times the diameter of the fermentation tank.
[0041] A defoamer replenishment device can be added to the top of the aforementioned tank to introduce defoamer, etc.
[0042] The stirring device of the intermediate stirring unit mentioned above supports forward and reverse rotation, and the tilt angle α of the stirring device of the intermediate stirring unit can be 45-60°.
[0043] The power mechanism corresponding to the stirring device mentioned above is an electric motor. The distributed stirring system for high-density microbial fermentation may also include:
[0044] Torque limiter, which is installed correspondingly to the stirring device, to provide overload protection for the stirring device;
[0045] A power ripple acquisition device is connected to the power mechanism to acquire the corresponding ripple current value. The metabolic waste gas concentration and torque limiter are both connected to the controller. A ripple current fluctuation threshold is first set in the program when feeding blockage occurs. By monitoring the ripple current value, a feeding blockage is identified when the current fluctuation exceeds the fluctuation threshold.
[0046] The connection and control between the controller and the aforementioned components can be achieved directly using existing technologies, and will not be elaborated upon here.
[0047] The specific configuration of the above-mentioned stirring unit can be illustrated as follows: (Combined with...) Figure 1 As shown, the tank body is equipped with a top stirring unit, a middle stirring unit, and a bottom stirring unit. The top stirring unit and the middle stirring unit are located on the side wall of the tank body 1. The top stirring unit includes a first stirring device 2, the middle stirring unit includes a second stirring device 3 and a third stirring device 4, and the first stirring device 2, the second stirring device 3, and the third stirring device 4 are arranged from top to bottom with adjacent stirring devices staggered. The bottom stirring unit includes a fourth stirring device 5, and an aeration disc 6 is provided on the inner side of the tank body 1 corresponding to the fourth stirring device 5. The first stirring device 2 can be an inclined blade agitator with four stirring blades, the second stirring device 3 can be a wide blade agitator with three or four stirring blades, and the third stirring device 4 can be an inclined blade agitator with three stirring blades.
[0048] All of the above-mentioned undisclosed matters can be implemented using existing technologies, so they will not be elaborated here.
[0049] Finally, it should be noted that in the description of this utility model, the terms "vertical," "upper," "lower," "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.
[0050] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set", "install", "connect", and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.
[0051] The above description, in conjunction with specific embodiments, provides a further detailed explanation of the present utility model. It should not be construed that the specific implementation of the present utility model is limited to these descriptions. For those skilled in the art, several simple deductions or substitutions can be made without departing from the concept of the present utility model, and all such deductions or substitutions should be considered to fall within the scope of protection defined by the claims submitted by the present utility model.
Claims
1. A distributed stirring system for high-density microbial fermentation, characterized in that, A distributed stirring system for high-density microbial fermentation is installed on the tank body of the fermenter. The distributed stirring system for high-density microbial fermentation includes at least three vertically layered stirring units, and each stirring unit includes at least one stirring device.
2. The distributed stirring system for high-density microbial fermentation according to claim 1, characterized in that, The distributed stirring system for high-density microbial fermentation also includes a controller and a sensor array. The sensor array and the power mechanism corresponding to the stirring device are both connected to the controller. The sensor group includes several sensors, which are correspondingly arranged with the stirring unit. The sensor group is used to detect and acquire data inside the tank in real time. The data inside the tank includes one or more of dissolved oxygen, cell density, metabolic waste gas concentration and fluid shear force, wherein the metabolic waste gas concentration includes one or more of carbon dioxide concentration, ethanol concentration and acetic acid concentration. The controller is used to acquire data from inside the tank and control the operation of each stirring unit based on that data.
3. The distributed stirring system for high-density microbial fermentation according to claim 1 or 2, characterized in that, Each stirring device in the distributed stirring system is equipped with a power mechanism, which drives the corresponding stirring device to rotate. Different stirring devices within the same stirring unit may have the same or different structures; stirring devices within different stirring units may have the same or different mechanisms.
4. The distributed stirring system for high-density microbial fermentation according to claim 1 or 2, characterized in that, The stirring device is a magnetic levitation stirring device.
5. The distributed stirring system for high-density microbial fermentation according to claim 1 or 2, characterized in that, The bottom stirring unit in the distributed stirring system for high-density microbial fermentation is a bottom stirring unit. The bottom stirring unit includes a stirring device, which is located in the middle of the bottom of the fermenter. An aeration device is correspondingly installed on the stirring device to form an aeration stirring device. The topmost stirring unit in the distributed stirring system for high-density microbial fermentation is the top stirring unit. The mixing unit located between the top mixing unit and the bottom mixing unit is the middle mixing unit. The mixing devices in both the middle mixing unit and the top mixing unit are located on the side wall of the tank, and the mixing devices in the middle mixing unit are inclined.
6. The distributed stirring system for high-density microbial fermentation according to claim 5, characterized in that, The diameter of the agitator blade in the bottom agitator unit is 0.25-0.35 times the diameter of the fermentation tank. The top of the tank is equipped with a defoamer replenishment device; The stirring device of the intermediate stirring unit supports both forward and reverse rotation, and the tilt angle of the stirring device of the intermediate stirring unit is 45-60°.
7. The distributed stirring system for high-density microbial fermentation according to claim 2, characterized in that, The sensor group includes a distributed light DO probe, a cell density detection module based on near-infrared and ultrasonic dual modes, and a gas mass spectrometer.
8. The distributed stirring system for high-density microbial fermentation according to claim 7, characterized in that, The accuracy of the distributed optical fiber DO probe is ±0.05 mg / L; The bacterial cell density detection module based on near-infrared and ultrasonic dual modes has an error of less than 3% and can monitor bacterial cell density online. The gas mass spectrometer is used to detect headspace gas inside the fermenter and monitor the concentration of metabolic waste gas online.
9. The distributed stirring system for high-density microbial fermentation according to claim 2, characterized in that, The power mechanism corresponding to the stirring device is an electric motor. The distributed stirring system for high-density microbial fermentation also includes: Torque limiter, which is installed correspondingly to the stirring device, to provide overload protection for the stirring device; A power ripple acquisition device is connected to the power mechanism to acquire the ripple current value corresponding to the power mechanism.