Modular Tubular Bioreactor for Flexible Culture Conditions
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Solution Overview
Problem
Conventional tubular bioreactors are not optimized for commercial production, lacking flexibility to accommodate different culture conditions, leading to issues such as stagnation zones, biofouling, inefficient light delivery, and inadequate nutrient and gas exchange, making them unsuitable for mixotrophic or heterotrophic cultures.
Innovation Solution
A modular bioreactor system comprising interchangeable modules for bioreactor, pump, and control units, with strategic lighting and cleaning systems, allowing for flexible configuration and operation in phototrophic, mixotrophic, or heterotrophic conditions, and enabling efficient light transmission and nutrient/gas management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single integrated tubular bioreactor system is used, then the system structure is simple, but the system cannot be reconfigured or repaired when components fail and lacks flexibility for different culture conditions
Solution Approach 1:
The bioreactor system is divided into modular segments including culture modules, pump modules, and control modules that can be independently configured, assembled, and disassembled. Each module can be optimized for specific functions while maintaining overall system flexibility for different culture conditions.
Solution Approach 2:
The system incorporates adjustable and reconfigurable components that allow dynamic adaptation to different culture conditions. Modules can be added, removed, or reconfigured based on specific phototrophic, mixotrophic, or heterotrophic culture requirements without redesigning the entire system.
2Reliability
If conventional tubular bioreactor design is used, then the design is simple, but stagnation zones and biofouling occur on inner surfaces
Solution Approach 1:
The system employs curved and angled tube configurations instead of straight vertical tubes. The tubes are arranged at specific angles and curves to eliminate dead zones where stagnation and biofouling typically occur, while maintaining efficient culture flow through the system.
3Adaptability or versatility
If tube diameter is increased for mixotrophic or heterotrophic systems, then nutrient and gas exchange is improved, but light path becomes insufficient for phototrophic growth
Solution Approach 1:
The bioreactor system is divided into specialized modules: phototrophic modules with smaller diameter tubes optimized for light penetration, and mixotrophic/heterotrophic modules with larger diameter tubes optimized for nutrient and gas exchange. This segmentation allows each module to be optimized for its specific function.
Solution Approach 2:
The modular design enables the system to perform multiple functions by combining different module types. The same platform can be configured for phototrophic, mixotrophic, or heterotrophic cultures by selecting and assembling appropriate modules, making the system universally applicable to different culture conditions.
4Use of energy by moving object
If conventional lighting system is used, then light application is simple, but light energy is wasted and harmful wavelengths may be applied
Solution Approach 1:
The lighting system uses adjustable parameters including wavelength selection, intensity control, and timing to optimize light delivery. LED technology provides precise spectral control to match microorganism requirements, while adjustable intensity and timing parameters further optimize energy efficiency and prevent harmful exposure.
Data Source
AI summary
Embodiments of a modular tubular bioreactor system for culturing an aqueous culture of microorganisms are described herein. The tubular bioreactor may comprise culture tubes configured in a vertically spaced and horizontally staggered arrangement to optimize the application of light to the culture in phototrophic and mixotrophic cultivation.