Bioreactor Gassing Control with Mass Flow Regulation
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Solution Overview
Problem
Conventional bioreactor systems lack flexibility in gas supply, limiting the ability to simultaneously and individually control multiple gas types and proportions, and require abstract unit entries for process regulation, which can lead to incorrect settings.
Innovation Solution
A bioreactor system with a gassing installation featuring multiple gas outlet lines connected to individual mass flow controllers and a controller that allows for precise regulation of gas supply, enabling simultaneous control of different gases and proportions, and allows entry of real physical values for process parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional gas supply system with shared gas lines and shut-off valves is used, then the device complexity is reduced, but the adaptability and flexibility in supplying different gases simultaneously and individually is limited
Solution Approach 1:
The gas supply system is segmented into separate gas lines for different gases (oxygen, nitrogen, carbon dioxide), with each line having its own mass flow controller. This segmentation allows independent control of each gas type, enabling simultaneous and individual regulation of multiple gases without requiring complex valve switching mechanisms.
Solution Approach 2:
Mass flow controllers are introduced as intermediary devices between the gas sources and the gassing devices. These controllers mediate the gas flow by providing precise, individual control of each gas type, eliminating the need for complex shut-off valve configurations while maintaining high adaptability in gas supply.
2Manufacturing precision
If abstract unit entries are used for process regulation, then the ease of operation is improved, but the manufacturing precision and risk of incorrect settings increases
Solution Approach 1:
The system allows entry of real physical values (e.g., specific gas flow rates in L/min, temperature in °C, pressure in bar) directly into the control unit, changing from abstract unit entries to concrete physical parameters. This enables precise process regulation while maintaining ease of operation, as users can input actual process values without needing to understand complex control units.
3Adaptability or versatility
If individual mass flow controllers are provided for each gas supply line, then the adaptability in controlling multiple gases simultaneously is improved, but the device complexity increases
Solution Approach 1:
Each mass flow controller is designed to universally control any gas type supplied through its dedicated line. The controllers perform the same function (flow regulation) for different gases (oxygen, nitrogen, carbon dioxide), providing multi-functionality that justifies the increased number of controllers. This universal design simplifies the overall system architecture compared to alternative solutions involving valve switching and manual control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible and precise gas supply, reduces the risk of incorrect settings, and supports seamless scaling up of processes by allowing entry of process-specific parameters, enhancing process control and efficiency.
Implementation Method 1
A mass flow controller is connected to a control unit and is arranged in each gas supply line and in each branch
Implementation Method 2
gassing devices (spargers) to introduce air and/or other gases directly into a liquid biological medium present in the vessel
Implementation Method 3
The first gassing channel is assigned a plurality of larger gas outlet openings having a diameter of more than 0.2 mm, e.g. 0.8 mm
Data Source
AI summary
A bioreactor system for carrying out a biological process including a vessel for receiving a liquid biological medium, and a gassing installation for controlled supply of different gases from gas sources into the vessel. The gassing installation has a plurality of gas outlet lines which open into gassing devices and/or into an overlay gas outlet in the interior of the vessel. Each gas outlet line is connected to a plurality of gas sources via a respective gas supply line or via a respective branch from a gas supply line. A mass flow controller connected to a controller is arranged in each gas supply line and in each branch. The system may include a controller with a master controller for a controlled variable, at least one sensor associated with the master controller, and one or more slave controllers having actuators, the manipulated variables of which purposefully influence the controlled variable.