Dual-Overflow Hydrocyclone for Biological Suspension Separation
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Solution Overview
Problem
Hydrocyclones used for separating biological suspensions face challenges in scaling up, resulting in low yield and recovery of products due to the formation of cyclones being sensitive to environmental conditions and requiring frequent tuning, which complicates their use in biological processes such as cell expansion and product harvesting.
Innovation Solution
A biological suspension separating system with a separation vessel that forms two nested vortices, utilizing a second overflow outlet to extract suspending solution from the 'eye' of the cyclone, along with adjustable fluid flow control means and sensors for optimizing separation, allowing for increased concentration of cells and media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single overflow outlet is used in a hydrocyclone for biological suspension separation, then the device structure remains simple, but the separation efficiency and product recovery are insufficient
Solution Approach 1:
The single overflow outlet is divided into two separate overflow outlets: a first overflow outlet for removing bulk liquid and a second overflow outlet positioned in the cyclone eye for removing concentrated cell-free supernatant. This segmentation allows simultaneous optimization of both liquid removal efficiency and cell concentration, resolving the contradiction between separation efficiency and device structure.
2Adaptability or versatility
If hydrocyclone operating parameters are frequently adjusted to adapt to different biological processes, then separation performance can be optimized, but the operational complexity and time required for tuning increase
Solution Approach 1:
The dual overflow outlet configuration provides universal applicability across different biological processes (cell culture, fermentation, downstream processing) without requiring frequent parameter adjustments. The system can handle various cell types and suspension characteristics through its inherent two-stage separation mechanism, eliminating the need for extensive operational tuning while maintaining high separation performance.
3Quantity of substance
If large volumes of suspension are processed in scaled-up hydrocyclones, then the system can handle industrial volumes, but the yield and recovery of product decrease
Solution Approach 1:
The separation process is segmented into two sequential stages: (1) bulk liquid removal through the first overflow outlet, and (2) concentrated cell-free supernatant removal through the second overflow outlet in the cyclone eye. This two-stage approach maintains high product recovery even at large processing volumes by systematically removing different fractions of the suspension, preventing the yield decline that occurs in single-stage systems.
4Ease of operation
If conventional hydrocyclone design is used for cell expansion and media replacement, then the device is simple and robust, but it cannot effectively concentrate cells or control media exchange
Solution Approach 1:
The device segments the overflow function into two distinct outlets with different functions: the first overflow outlet handles bulk media removal while the second overflow outlet in the cyclone eye concentrates and removes cell-free supernatant. This segmentation enables effective cell concentration and controlled media exchange while preserving the robust, simple hydrocyclone structure with no moving parts.
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
The system effectively increases the concentration of cells and media, improving yield and recovery rates by controlling fluid flow and vortex dynamics, making it suitable for large-scale biological processes.
Implementation Method 1
The fluid is fed into the separation vessel transverse to (for example, perpendicular to) and eccentric to a longitudinal axis of the separation vessel such that it creates a cyclone effect in the vessel centred about (and therefore coaxial to) the longitudinal axis
Implementation Method 2
two vortices are formed inside the separation vessel, one nested within the other and rotating in an opposite direction to the other
Implementation Method 3
denser and/or more massive particles in the fluid travel around the sides of the separation vessel and out through an outlet at one end of the separation vessel (the underflow outlet)
Data Source
AI summary
A separating system, for example for separating material from a suspension such as a biological suspension, is disclosed herein. The system comprises a separation vessel arranged to enable the formation of a cyclone therewithin. For example, the separation vessel may be at least partially conical in shape for enabling the formation of a cyclone therewithin. The separation vessel comprises a fluid inlet, an underflow outlet, a first overflow outlet for removing fluid from a first region inside the separation vessel, and a second overflow outlet for removing fluid from a second region inside the separation vessel.