Fermenter Two-Phase Injectors Oxygen Transfer
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Solution Overview
Problem
Existing fermenters for high-oxygen demanding fermentation processes face challenges in efficiently delivering oxygen and maintaining sterility, leading to suboptimal productivity and increased operational costs.
Innovation Solution
The development of a fermenter equipped with two-phase injectors that utilize a liquid stream to break up oxygen into fine bubbles, combined with a circulation loop for liquid supply and sterilizable design, addresses the challenges of oxygen delivery and sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional stirred tank fermenters are used for high oxygen demanding fermentation, then oxygen can be delivered to the fermentation broth, but energy consumption is high and oxygen transfer efficiency is limited
Solution Approach 1:
The invention removes the traditional stirrer mechanism from the fermenter system and replaces it with ejectors that utilize the fermentation broth's own circulation flow to generate oxygen transfer. This extraction of the mechanical agitation component eliminates the high energy consumption associated with continuous stirring while maintaining effective oxygen delivery through the ejector-induced liquid-gas mixing.
Solution Approach 2:
The fermentation broth itself serves as the driving fluid for the ejectors, utilizing its own circulation flow to power the oxygen injection process. The circulating broth provides the liquid phase that, when mixed with gas through the ejector, creates the fine bubble dispersion necessary for efficient oxygen transfer without requiring external mechanical energy input.
2Productivity
If spargers are used to deliver air bubbles in bubble column fermenters, then oxygen transfer occurs as bubbles rise, but bubble size remains large and oxygen transfer efficiency is suboptimal
Solution Approach 1:
The ejector acts as an intermediary device that transforms the interaction between gas and liquid phases. Instead of directly introducing large bubbles through a sparger, the ejector uses the circulating liquid broth as a mediator to break up the gas into fine bubbles through high-velocity mixing, dramatically increasing the total bubble surface area and improving oxygen transfer efficiency.
Solution Approach 2:
The invention changes the physical parameters of bubble formation by using ejector-induced high-velocity flow to create extremely fine bubbles with much smaller diameter and larger total surface area compared to traditional spargers. This parameter change in bubble size distribution directly enhances the oxygen transfer rate.
3Productivity
If circulation loops are implemented for liquid supply to two-phase injectors, then oxygen delivery is improved, but maintaining sterility becomes more challenging
Solution Approach 1:
The circulation loop serves multiple functions simultaneously: it provides the liquid phase for the two-phase injectors, maintains broth mixing and homogeneity, and when equipped with sterilizable components, ensures sterility maintenance. The multi-functionality of the circulation system allows it to address both oxygen delivery and sterility requirements through integrated design.
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 solution enhances oxygen transfer efficiency, reduces energy consumption, and lowers operational costs while maintaining the sterility required for industrial fermentation processes.
Implementation Method 1
one or more two-phase injectors for supplying oxygen, at least one loop withdrawing fluid from the fermenter and circulating the fluid to provide liquid for the two-phase injectors
Data Source
AI summary
Disclosed is a fermenter comprising one or more two phase injectors for providing oxygen for the fermentation and a circulation loop, circulating the fermentation broth and providing liquid for the two-phase injectors. Further disclosed is a fermentation plant comprising one or more fermenters of the invention and utility for the fermenters. Also disclosed is the use of the fermenters for the production of a fermentation product such as an enzyme.