Fed-batch Fermentation Bioreactor Filling Optimization
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Solution Overview
Problem
Industrial fermentation processes often operate at suboptimal capacity due to low bioreactor filling levels in fed-batch mode, leading to wasted fermentation capacity, particularly in large bioreactors, as they are mostly filled with air rather than fermentation broth.
Innovation Solution
A method involving a series of connected bioreactors where fermentation broth is transferred and reused, with each bioreactor operating in fed-batch culture, allowing for continuous nutrient supplementation and optimization of broth transfer times and amounts using a dynamic process model to maximize productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fed-batch fermentation is used in conventional mode, then the process is simple to operate, but the bioreactor filling level is low resulting in wasted fermentation capacity
Solution Approach 1:
The fermentation process is divided into multiple sequential fed-batch stages within the same bioreactor. After each fed-batch cycle completes, the bioreactor is not emptied but rather a portion of the broth is retained and a new fed-batch cycle begins, creating segmented continuous operation that maintains high filling levels while preserving operational simplicity
Solution Approach 2:
The system implements continuous useful action by immediately starting a new fed-batch cycle after the previous one completes, without emptying the bioreactor. This continuous operation eliminates idle time and maintains the bioreactor at high filling levels, maximizing productivity while keeping the operation straightforward
2Quantity of substance
If large bioreactors are operated in conventional fed-batch mode, then the equipment is already invested, but a significant part is filled with air rather than fermentation broth wasting capital
Solution Approach 1:
Instead of discarding the fermentation broth by emptying the bioreactor after each fed-batch cycle, the system recovers and retains a portion of the broth for the next cycle. This recovery approach ensures the bioreactor remains filled with productive fermentation broth rather than air, eliminating capital waste on large bioreactor volumes
3Reliability
If the bioreactor is emptied and sterilized between batches, then contamination is prevented, but the cycle time increases reducing overall productivity
Solution Approach 1:
The system performs preliminary sterilization of the bioreactor before the first fed-batch cycle begins. Subsequent cycles utilize the retained broth and bioreactor environment without requiring repeated sterilization, thereby preventing contamination while eliminating the time-consuming emptying and re-sterilization steps that would reduce productivity
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
This approach increases microorganism cultivation productivity by ensuring bioreactors are filled to higher levels, optimizing resource utilization, and enhancing overall fermentation efficiency.
Implementation Method 1
a fermentation plant comprising at least three bioreactors which are connected with means for transporting fermentation broth between the bioreactors
Data Source
AI summary
The present invention relates to a method for cultivating a microorganism, comprising the steps of(i) adding into a first bioreactor a medium and an inoculum comprising the microorganism and producing a fermentation broth in fed-batch culture; and(ii) adding into a second bioreactor a second medium and part of the fermentation broth from step (i) and producing a second fermentation broth in a second fed-batch culture; and(iii) adding into a next bioreactor a next medium and a part of the fermentation broth from step (ii), and producing a next fermentation broth in a next fed-batch culture,wherein a feed is introduced into the first, second and next bioreactor.