Fermentation Sparger Segmentation for Uniform Gas Uptake

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Fermentation systems with a single sparger often experience significant variations in volumetric uptake rate (VUR) of reactive gaseous components across the fermentation vessel, leading to uneven metabolic process performance and reduced product yields due to gradients in reactive gas availability.

Innovation Solution

The implementation of multiple spargers spaced along the fermentation vessel's length, each establishing a mixing zone with a substantially uniform VUR, controlled by adjusting gas introduction rates to maintain consistent reactive gas distribution and promote desired metabolic pathways.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single sparger is used to introduce gas bubbles into the fermentation broth, then the device complexity is reduced, but significant variations in volumetric uptake rate occur across the fermentation vessel leading to uneven metabolic performance

Engineering Contradiction:

Improvenumber of spargersVSAvoiduniformity of volumetric uptake rate

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The single sparger is divided into multiple spargers distributed along the fermentation vessel. Each sparger introduces gas bubbles into a specific region, creating multiple mixing zones that each achieve uniform volumetric uptake rate. This segmentation resolves the contradiction by distributing the gas introduction function across multiple locations, eliminating the VUR gradients that occur with a single sparger while maintaining relatively simple device structure.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If multiple spargers are used to establish multiple mixing zones with uniform VUR, then the uniformity of volumetric uptake rate is improved, but the device complexity increases

Engineering Contradiction:

Improveuniformity of volumetric uptake rateVSAvoidnumber of spargers

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Each sparger is positioned and configured to create a local mixing zone with specific characteristics. The spargers are spaced apart along the vessel length, with each one optimizing gas bubble release for its local region. This local quality approach allows each sparger to independently control the VUR in its zone, achieving overall uniformity without requiring complex centralized control systems.

Inventive Principle:

Principle #3Local quality

3Productivity

If gas is introduced at high rates to ensure sufficient reactive gaseous component availability, then the productivity is improved, but significant VUR gradients occur reducing metabolic process consistency

Engineering Contradiction:

Improveproduct yieldVSAvoidconsistency of metabolic process

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

High gas introduction rates are segmented across multiple spargers distributed along the vessel rather than concentrated at one location. This allows the total gas flow required for high productivity to be distributed evenly, maintaining consistent VUR across all regions while achieving the necessary overall gas supply for high product yield.

Inventive Principle:

Principle #1Segmentation

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 significantly reduces VUR gradients, enhancing metabolic process consistency and increasing product yields by ensuring uniform reactive gas availability across the fermentation broth, thereby improving microbial organism performance and product production.

Implementation Method 1

bubbles of a gas including the reactive gaseous component can be introduced into the fermentation broth by a sparger located near the bottom of the vessel

Methodology Applied

Scientific EffectGas-liquid mass transfer: Absorption (physical)

Implementation Method 2

The bubbles of the gas also can mix the fermentation broth within the vessel

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 3

Each mixing zone can have substantially the same volumetric uptake rate of the reactive gaseous component by the fermentation broth

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20210079334A1Fermentation systems and methods with substantially uniform volumetric uptake rate of a reactive gaseous component

Publication Date: 2021.03.18 GENOMATICA INC

AI summary

Under one aspect, a fermentation system includes a fermentation vessel having a straight wall length L and an inner diameter D. The fermentation system also can include a source of a gas including a reactive gaseous component. The fermentation system also can include spargers spaced apart from one another along the straight wall length L of the fermentation vessel and configured to introduce bubbles of the gas into fermentation broth within the fermentation vessel. The release of the bubbles of the gas by each of the spargers can establish a respective mixing zone within the fermentation broth within the fermentation vessel. Each mixing zone can have substantially the same volumetric uptake rate of the reactive gaseous component by the fermentation broth as each other mixing zone.