Process Tank Sampling Device with Pressure-Driven Backflow Prevention
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Solution Overview
Problem
Existing sampling devices for process tanks, particularly in bioprocesses, face challenges in preventing contamination of the tank contents during sampling, as they may allow non-sterile substances to enter due to leaks or inadequate sterilization, and often require standardized adapters that are not available for small fermenters in laboratory settings.
Innovation Solution
A device with a first receptacle and a liquid line connected to the process tank, featuring a valve assembly and pressure sensors to maintain a pressure difference greater than zero between the tank and the receptacle, ensuring that liquid is drawn away from the tank and preventing backflow, thus preventing contamination, even if the system is not perfectly sterile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sampling device transports liquid back into the process tank, then the sampling device can be flushed to prevent contamination, but non-sterile substances may enter the process tank due to leaks or inadequate sterilization
Solution Approach 1:
The patent inverts the traditional sampling approach by preventing liquid from flowing back into the process tank through a one-way valve assembly. Instead of flushing the sampling line back into the tank, the system uses a check valve to allow liquid to flow only in the sampling direction, thereby eliminating the risk of contaminating the process tank while maintaining the ability to flush the sampling line into a separate waste container.
Solution Approach 2:
The patent segments the sampling system into distinct flow paths: a sampling path that draws liquid from the process tank through a sterile filter, and a separate flushing path that directs waste liquid to a different container. This segmentation prevents potential contaminants from entering the process tank by creating isolated flow routes with dedicated one-way valves for each direction.
2Reliability
If a bidirectional pump is used to flush the sampling line, then the sampling device can be sterilized, but the complexity of the system increases and the risk of contamination during operation rises
Solution Approach 1:
The patent extracts the flushing function from the main sampling line by providing a separate flushing path that bypasses the process tank. The one-way valve assembly allows the sampling line to be flushed in a single direction toward a waste container, eliminating the need for bidirectional pumping while maintaining effective sterilization capability through simplified unidirectional flow control.
3Reliability
If standardized adapters are required for sampling devices, then connection reliability is improved, but compatibility with small fermenters in laboratory settings is reduced
Solution Approach 1:
The patent designs a universal sampling device with standardized connection interfaces that can adapt to different fermenter sizes and types. The one-way valve assembly and sampling mechanism are configured to work with various adapter configurations, enabling the same core device to serve both industrial-scale process tanks and laboratory-scale small fermenters through interchangeable connection components.
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 device effectively prevents chemical or biological contamination of the process tank by maintaining a pressure difference that ensures liquid is transported away from the tank and not back into it, even in the presence of leaks or contamination in the system, and is adaptable for use with small fermenters through modular design.
Implementation Method 1
there is a pressure difference p1-p2 between a pressure p1 at a first end of the first liquid line and a pressure p2 at a second end of the first liquid line that is greater than or equal to zero
Data Source
AI summary
The application discloses a device for drawing a liquid from a process tank to be protected from contamination, including: a first receptacle for receiving the liquid withdrawn from the process tank; a first liquid line connecting the process tank with the first receptacle; and at least one first valve assembly disposed in the first liquid line and designed to block or release liquid transport through the first liquid line. The device includes at least one pressure sensor for detecting a pressure within the first receptacle. The device is designed such that a pressure difference between the first and the second ends of the first liquid line is greater than a predetermined minimum value when the first liquid line is connected with the process tank and the process tank is to be protected from contamination.