Superheated Water Sterilization for Bioreactor Corrosion and Energy
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Solution Overview
Problem
Existing methods for sterilizing bioreactor systems used in cell-based animal food production face challenges such as contamination control, energy inefficiency, and corrosion due to the use of steam sterilization.
Innovation Solution
The use of superheated water, heated above the atmospheric boiling point and pressurized above atmospheric pressure, for sterilization-in-place (SIP) within closed bioreactor systems, which reduces energy consumption and minimizes corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam sterilization is used to prepare process equipment for cultivation, then contamination risk is reduced, but energy losses occur and equipment corrosion increases
Solution Approach 1:
The patent changes the physical parameters of the sterilization medium by using superheated water instead of saturated steam. This involves heating water above its saturation temperature at a given pressure, creating a liquid state that maintains higher temperature without phase change, thereby improving energy efficiency while maintaining sterilization effectiveness.
Solution Approach 2:
The patent converts the typically harmful effect of high-energy steam condensation (which causes corrosion) into a beneficial process. By using superheated water, the high temperature provides effective sterilization without the aggressive condensation behavior of steam, thus eliminating corrosion while maintaining contamination control.
2Reliability
If steam sterilization is used to prepare process equipment for cultivation, then contamination risk is reduced, but equipment corrosion increases
Solution Approach 1:
The patent changes the physical state and temperature parameters of the sterilization medium. By using superheated water at controlled temperatures and pressures, it achieves effective sterilization without the aggressive condensation behavior of saturated steam that causes equipment corrosion.
Solution Approach 2:
The patent eliminates the harmful condensation effect of steam by using superheated water. The high temperature of superheated water provides effective sterilization without phase change and direct contact condensation, thus protecting equipment from corrosion while maintaining contamination control.
3Temperature
If saturated steam is used for sterilization, then high temperature sterilization is achieved, but heat transfer efficiency decreases due to poor heat conduction of air and CO2
Solution Approach 1:
The patent changes the temperature and pressure parameters to create superheated water, which has superior heat transfer properties compared to saturated steam. The liquid state of superheated water allows for more efficient heat conduction through the medium, improving overall heat transfer efficiency while maintaining high sterilization temperatures.
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
Superheated water sterilization effectively reduces contamination risks, enhances energy efficiency, and minimizes equipment corrosion compared to traditional steam sterilization methods.
Implementation Method 1
During sterilization, steam denatures proteins of organisms, thereby reducing the risk of contamination
Implementation Method 2
circulating heated fluid through the bioreactor system at a temperature above an atmospheric boiling point of the heated fluid
Implementation Method 3
pressurizing at least one pressure vessel in a bioreactor system at a pressure above atmospheric pressure
Data Source
AI summary
The present disclosure relates to systems, apparatuses, and methods for sterilizing a closed bioreactor system utilizing superheated water. In particular, in one or more implementations, the disclosed methods include circulating a heated fluid within at least one pressure vessel of a bioreactor system at a pressure above an atmospheric pressure and a temperature above an atmospheric boiling point for the heated fluid. In some implementations, in response to circulating superheated water within a closed bioreactor system for a predetermined dwell time, the disclosed methods include reducing a pressure within the closed bioreactor system to cause the superheated water to evaporate therein. Also, in one or more implementations, the disclosed systems include a combination superheated water and steam generator, a superheated water storage tank, and/or a stratified energy storage tank for utilization in sterilization-in-place and other procedures for producing comestible cell-based food products.