Bioreactor Condenser with Recycled Moisture Control
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Solution Overview
Problem
Current condenser designs for bioreactors are complex, costly, and non-disposable, leading to moisture condensation issues that result in wasted condensate and bioreactor reaction volume loss, affecting the osmolality of the reaction mixture.
Innovation Solution
A system comprising a contact condenser container fluidically coupled to the bioreactor with a condensate accumulator and control devices to recycle condensate, reducing moisture content in the gas stream and minimizing waste by reintroducing cooled condensate to enhance condensation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a condenser is used to condense moisture in the bioreactor gas stream, then moisture content in the gas stream is reduced, but the condensate is wasted by being poured into the environment
Solution Approach 1:
The patent recovers condensate that would otherwise be discarded by implementing a system where condensate accumulates in an accumulator and is then reintroduced into the bioreactor through a condensate reintroduction line. This prevents waste of the condensate while maintaining system simplicity through straightforward fluid pathway design.
Solution Approach 2:
The condensate serves multiple functions in the system: it is first collected as a byproduct of condensation, then stored in an accumulator, and finally reintroduced into the bioreactor to maintain reaction volume and osmolality. This multi-functional use of condensate reduces waste while avoiding complex disposal mechanisms.
2Quantity of substance
If water vapor from the bioreactor reaction mixture is lost over time, then the bioreactor reaction volume decreases, but the osmolality of the reaction mixture changes to an undesirable level
Solution Approach 1:
The system implements feedback by continuously monitoring the condensation process and automatically reintroducing condensate into the bioreactor. The condensate accumulator and control system ensure that condensed water vapor is returned to the reaction mixture, maintaining both volume and osmolality at desired levels through closed-loop moisture management.
Solution Approach 2:
The bioreactor system serves itself by capturing its own lost water vapor through condensation and automatically reintroducing it through the condensate reintroduction system. This self-service mechanism maintains reaction volume and osmolality without requiring external intervention or complex control systems.
3Ease of manufacture
If currently available condenser designs are used, then moisture condensation is achieved, but the design is complex and costly requiring special tooling and specially molded or machined components
Solution Approach 1:
The condensation system is segmented into distinct functional components: a condenser for moisture removal, a condensate accumulator for storage, and a reintroduction mechanism. Each component can be manufactured independently using standard processes, avoiding the need for complex integrated designs requiring special tooling or specially molded components.
Solution Approach 2:
The patent employs a disposable bioreactor system where the condenser and associated components are designed as single-use, cost-effective units. This approach eliminates the need for expensive, complex, reusable designs with special tooling requirements, as each disposable unit can be manufactured simply and discarded after use.
Data Source
AI summary
Disclosed herein is a system and method for condensing moisture in a gas stream entering or leaving a bioreactor, the system comprising: a contact condenser container fluidically coupled to the bioreactor through an exhaust line; a condensate accumulator fluidically coupled to the contact condenser container through at least a first condensate line and a second condensate line; the condensate accumulator further fluidically coupled to the bioreactor through a condensate overflow line; a first condensate control device disposed on the first condensate line and configured to control a flow of condensate leaving the contact condenser container and entering the condensate accumulator; and a second condensate control device disposed on the second condensate line and configured to control a flow of condensate leaving the condensate accumulator to be mixed with the gas stream.