External Loop Fermentation Cooling and Aeration
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Solution Overview
Problem
Large-scale aerobic fermentation systems face challenges in maintaining optimal temperature control and dissolved oxygen levels, particularly at elevated cell growth rates and densities, leading to inefficient protein production and increased costs.
Innovation Solution
The system incorporates an external loop with a cooling apparatus and an aeration apparatus, where the cooling apparatus precedes or follows the aeration apparatus, using nanobubble generators and heat exchangers to maintain temperature between 20° C and 40° C and dissolved oxygen levels above 15%, with a media metering apparatus and separation apparatus for efficient biomass growth and protein extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cooling and aeration systems are used in large-scale aerobic fermentation, then temperature control and oxygen supply are provided, but temperature control efficiency deteriorates and oxygen transfer rates are insufficient at elevated cell growth rates and densities
Solution Approach 1:
The external loop system segments the fermentation process by diverting a portion of the fermentation broth through separate cooling and aeration pathways. This allows independent optimization of temperature control and oxygen supply without interfering with the main fermentation vessel operations, thereby maintaining effective temperature control even at elevated cell growth rates.
Solution Approach 2:
The external loop acts as an intermediary system between the fermentation vessel and the cooling/aeration apparatus. By using this intermediate pathway, the system can apply intensive cooling and aeration treatments to the diverted broth portion without directly impacting the main vessel, thus improving overall temperature control efficiency and oxygen transfer rates.
2Productivity
If conventional cooling and aeration systems are used in large-scale aerobic fermentation, then temperature control and oxygen supply are provided, but oxygen transfer rates remain insufficient
Solution Approach 1:
The external loop system segments the oxygen supply process by providing a dedicated aeration pathway for the diverted fermentation broth. This separate aeration system can operate at optimized conditions with high oxygen transfer efficiency, directly addressing the insufficient dissolved oxygen levels that limit protein production efficiency in conventional systems.
Solution Approach 2:
The external loop system enables continuous cooling and aeration of the fermentation broth through the external pathway. This continuous action ensures that oxygen supply is maintained at optimal levels throughout the fermentation process, supporting sustained high protein production efficiency without the interruptions or limitations of conventional intermittent aeration.
3Temperature
If external loop with cooling and aeration apparatus is implemented, then temperature control and oxygen transfer are improved, but device complexity increases
Solution Approach 1:
The external loop system is designed to perform multiple functions within a single integrated configuration. The same external loop infrastructure supports both cooling and aeration operations, allowing the system to achieve improved temperature control and oxygen transfer simultaneously without requiring entirely separate systems, thereby limiting the increase in device complexity.
Solution Approach 2:
The system performs preliminary cooling and aeration actions on the fermentation broth before it returns to the main fermentation vessel. By pre-conditioning the broth in the external loop, the system achieves better temperature control and oxygen distribution with simpler in-vessel equipment, thus improving performance while managing overall system complexity.
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 configuration enhances temperature control and oxygen transfer, improving biomass growth rates and protein production efficiency while reducing operational costs by maintaining optimal conditions and increasing oxygen transfer rates.
Implementation Method 1
a cooling apparatus; and an aeration apparatus in fluid communication with the cooling apparatus
Implementation Method 2
the aeration apparatus is configured to introduce an oxygen-containing gas into the fermentation broth
Implementation Method 3
an aeration apparatus in fluid communication with the cooling apparatus
Implementation Method 4
the aeration apparatus comprises a nanobubble generator configured to produce bubbles of oxygen having a median diameter of less than about 200 nanometers
Data Source
AI summary
The present disclosure relates to an integrated methanol synthesis and fermentation system for the production of whole ells and biomolecules, and methods of using the same. In one embodiment, an apparatus comprises an inlet port; a pump in fluid communication with the inlet port to pump in a fermentation broth from a fermentation vessel; a cooling system; an aeration system in fluid communication with the cooling system; and an outlet port to reintroduce the fermentation broth into the fermentation vessel.