Fermenter Gas-Liquid Interface Detection Using Multi-Sensor Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing culture devices for polyhydroxyalkanoate production in fed-batch cultures face challenges in accurately detecting the gas-liquid interface, particularly when liquid density changes, leading to inefficient use of fermenter volume and reduced productivity due to bubble holding.
Innovation Solution
A culture device equipped with a liquid surface sensor for detecting foam layer height and at least two pressure sensors below the gas-liquid interface, allowing accurate detection of the gas-liquid interface and reducing bubble holding by adjusting culture conditions such as carbon source addition rate, stirring power, and bubbling conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pressure sensor is installed in the liquid phase to detect the gas-liquid interface, then the device structure is simple, but the measurement precision deteriorates when liquid density changes during culture
Solution Approach 1:
The single pressure sensor is segmented into multiple pressure sensors (at least two) installed at different locations in the liquid phase. This segmentation allows the system to detect pressure variations at multiple points, enabling accurate determination of the gas-liquid interface position even when liquid density changes during culture, thereby resolving the contradiction between simple structure and precise measurement.
2Device complexity
If bubble holding is not detected and managed, then the culture process is simple, but the volumetric capacity utilization and productivity deteriorate
Solution Approach 1:
The multiple pressure sensors provide continuous feedback on the gas-liquid interface position and bubble holding conditions. This feedback enables real-time monitoring and control of bubble accumulation, allowing operators to adjust culture conditions to maintain optimal volumetric capacity utilization, thereby resolving the contradiction between simple operation and high productivity.
3Measurement precision
If multiple pressure sensors are installed below the gas-liquid interface to improve detection accuracy, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
Instead of installing pressure sensors at every possible location, the invention applies partial action by installing at least two pressure sensors at strategically selected positions in the liquid phase. This partial deployment provides sufficient data to accurately determine the gas-liquid interface position without the excessive complexity of comprehensive sensor coverage, balancing measurement precision with device 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
Enables precise management of the gas-liquid interface and foam layer, improving production efficiency by optimizing the gas holdup ratio and enhancing productivity per batch.
Implementation Method 1
a pressure sensor for detecting a liquid surface height from the bottom of the fermenter to a gas-liquid interface
Implementation Method 2
a liquid surface sensor for detecting a foam layer height from the bottom of a fermenter to the top of a foam layer
Data Source
AI summary
An object of the present invention is to provide a culture device capable of accurately detecting the gas-liquid interface of a culture solution in a fermenter. The above problem is solved by provided a culture device that includes: a liquid surface sensor for detecting a foam layer height from the bottom of the fermenter to the top of a foam layer; and a pressure sensor for detecting a liquid surface height from the bottom of the fermenter to a gas-liquid interface, the culture device having installed at least two pressure sensors below the gas-liquid interface, the at least two pressure sensors each being the pressure sensor.