Heat Exchange Module for Flexible Bioreactor Bags
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Microbial bioreactors face challenges in heat removal due to the poor heat conductivity of polymeric materials used in flexible bags, which can lead to inefficient cooling of microbial cell cultures that generate significant heat during fermentation processes.
Innovation Solution
A heat exchange module is integrated into the reactor system, featuring a thermally conductive surface and a fluid circulation path to enhance heat transfer, and a jacketed, tiered baffle bioreactor tank that routes liquid coolant around the tank surface to efficiently dissipate heat from flexible bags.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If polymeric materials are used for flexible bioreactor bags, then flexibility and ease of operation are improved, but heat transfer efficiency deteriorates
Solution Approach 1:
The patent applies composite materials by combining polymeric flexible bag material with thermally conductive materials (such as metal plates, extrusions, or coatings) to create a hybrid structure. The polymeric material provides flexibility and ease of operation, while the thermally conductive material embedded in or attached to the bag walls enhances heat transfer efficiency. This composite approach resolves the contradiction by integrating both required properties in a single system.
2Quantity of substance
If vigorous agitation and high air flow rates are used in stainless steel fermentors, then oxygen supply is improved, but heat generation increases
Solution Approach 1:
The patent extracts the heat removal function from the agitation system by implementing a separate, dedicated thermal management system using flexible bags with enhanced heat transfer surfaces. Instead of relying on vigorous agitation (which generates frictional heat) for both oxygenation and cooling, the invention separates these functions: agitation provides oxygen supply while the specialized heat exchange surfaces handle heat removal, thereby reducing overall heat generation.
3Loss of energy
If cooling coils are added to remove heat, then heat removal capacity is improved, but device complexity increases
Solution Approach 1:
The patent merges the containment function and heat exchange function into a single integrated structure. The flexible bag itself, rather than being a simple container, is designed with embedded thermally conductive elements that serve dual purposes: maintaining bag integrity/shape and facilitating heat transfer. This integration eliminates the need for separate cooling coils and reduces overall system complexity while maintaining effective heat removal capacity.
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
The solution effectively addresses the heat removal challenge by improving heat transfer efficiency, allowing for faster cooling of microbial cultures and maintaining optimal temperature conditions during fermentation.
Implementation Method 1
a heat exchange module adapted to contact the inner reactor container, the body further including at least one thermally conductive surface adapted to contact the inner container to facilitate heat transfer
Implementation Method 2
a heat exchanger disposed within the module body having a fluid circulation path through which a heat exchange fluid can be circulated
Implementation Method 3
a jacketed, tiered baffle bioreactor tank that routes liquid coolant around the tank surface to efficiently dissipate heat from flexible bags
Implementation Method 4
routes liquid coolant around the tank surface to efficiently dissipate heat
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A heat exchange module for use in a chemical, pharmaceutical or biological reactor system can include a body configured to be disposed in the reactor system having an inner replaceable reactant container is disclosed. The body can further include at least one thermally conductive surface adapted to contact the inner replaceable reactant container to facilitate heat transfer. Furthermore, the heat exchange module can include a heat exchanger disposed within the module body and can include a fluid circulation path through which a heat exchange fluid can be circulated.