Jet Mixer Bioreactor for Low-Shear Microorganism Mixing

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Solution Overview

Problem

Bioreactors face challenges in efficiently controlling dissolved oxygen levels and agitation speed, which can be detrimental to fragile microorganisms due to high power consumption and risk of damage, especially in processes involving mammalian cells.

Innovation Solution

The implementation of jet mixing techniques and equipment, such as jet aeration and jet flow agitation, which enhance mass transfer and reaction rates while minimizing shear and temperature increases, allowing for increased solids levels and efficient bioprocessing without harming sensitive microorganisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If traditional agitation methods are used to enhance oxygen transfer, then dissolved oxygen level is improved, but shear damage to fragile microorganisms increases

Engineering Contradiction:

Improvedissolved oxygen levelVSAvoidshear damage to microorganisms

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent replaces traditional mechanical agitation systems with a jet mixing system that uses fluid dynamics. Gas is injected through nozzles to create jets that induce circulation and mixing without mechanical contact, thereby eliminating shear damage to fragile microorganisms while still achieving effective oxygen transfer and mixing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention uses gas injection through nozzles to create high-velocity jets that drive fluid circulation and mixing. The gas flow rate is controlled at less than 0.2 vvm to achieve adequate oxygen transfer while minimizing harmful effects, utilizing pneumatic principles to replace mechanical agitation.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Quantity of substance

If agitation speed is increased to improve mixing and oxygen transfer, then mass transfer is enhanced, but power consumption increases

Engineering Contradiction:

Improvemass transfer rateVSAvoidpower consumption

Core Design Contradiction:

Quantity of substanceVSUse of energy by moving object

Solution Approach 1:

The patent replaces energy-intensive mechanical agitation with a gas-driven jet mixing system. Gas is injected through nozzles to create circulation patterns that achieve effective mixing and mass transfer without the high power consumption associated with traditional mechanical agitators operating at high speeds.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the mixing mechanism from mechanical rotation to gas flow dynamics. By controlling gas flow rate at less than 0.2 vvm and adjusting nozzle characteristics, the system achieves effective mass transfer with significantly reduced energy input compared to high-speed mechanical agitation.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If traditional mixing equipment is used to increase solids level, then process efficiency is improved, but shear damage to sensitive ingredients increases

Engineering Contradiction:

Improveprocess efficiencyVSAvoidshear damage to microorganisms and enzymes

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical mixing equipment with a jet mixing system that uses gas injection to create circulation and mixing. This allows solids levels to be increased and processing to proceed more rapidly without the shear damage caused by mechanical agitators, as the gas jets gently induce fluid motion without direct mechanical contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention uses controlled gas injection through nozzles to create circulation patterns that enhance mixing and allow higher solids levels. The gas flow rate is maintained at less than 0.2 vvm to achieve adequate mixing efficiency while protecting sensitive microorganisms and enzymes from shear damage.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 enables more rapid, cost-effective bioprocessing with improved product concentration and maintains microorganisms in a viable condition, as it reduces shear and temperature impacts, allowing for precise control of oxygen levels and efficient mixing with low energy consumption.

Implementation Method 1

jet mixing techniques, including for example jet aeration and jet flow agitation

Methodology Applied

Scientific EffectJet aeration: Jet

Implementation Method 2

enhance mass transfer, and as a result reaction rates in a mixture

Methodology Applied

Scientific EffectMass transfer: Diffusion

Implementation Method 3

jet mixing techniques, including for example jet aeration and jet flow agitation

Methodology Applied

Scientific EffectJet flow agitation: Jet

Implementation Method 4

provide good wetting, dispersion and mechanical disruption

Methodology Applied

Scientific EffectFluid circulation: Convection

Data Source

PatentUS9284586B2Bioprocessing

Publication Date: 2016.03.15 XYLECO INC

AI summary

Bioreactors are provided that include a vessel and a jet mixer disposed in the vessel. Methods that utilize the bioreactors are provided, involving placing a microorganism or cells and a fluid medium in the bioreactor.