Bioreactor Design. Daniel Egger,

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1 Bioreactor Design Daniel Egger, Infors AG, Headoffice, Switzerland, Rittergasse 27, CH-4103 Bottmingen,

2 Agenda What is «Bioreactor Design»? Why are different bioreactor designs needed? Specific bioreactor designs

3 What is a bioreactor? A device or system that: supports a biologically active environment. Source: Wikipedia,

6 What is bioreactor design?

7 What is bioreactor design? Functionality: depending on application and area of use.

11 Bioreactor applications Microbial Cell culture Biofuel 2 nd generation Biofuel 3 rd generation Syngas

12 Bioreactor applications Microbial Cell culture Biofuel 2 nd generation Biofuel 3 rd generation Syngas

13 Extract of specific requirements Bacteria Cell culture Doubling time OUR (oxygen uptake rate) Sensitivity (shear ) ~ 30 min ~ mmol Cell -1 h -1 Low ~ 12 to 48 h ~ mmol Bact. -1 h -1 High

14 Comparison microbial & cell bioreactor Vessel Dimensions Stirrer Submerse Air, O 2, (N 2 ) Gassing Head space: Air, CO 2 Submerse: Air, O 2, N 2 CO2

15 Microbial fermentation: agitation Rushton blades Baffles Smaller bubbles = higher K L a Sparger

16 Extract of specific functions: agitator Bacteria fermentation Cell culture Even nutrient & temp. distribution High oxygen transfer (K L a) Energy input Yes Main function High Main function Low Low

17 Bioreactor applications Microbial Cell culture Biofuel 2 nd generation Biofuel 3 rd generation Syngas

18 Biofuel Fuel that contains energy from geologically recent carbon fixation, produced from living organisms. Source: Wikipedia,

19 Biofuel 1 st generation 2 nd generation 3 rd generation Bioethanol, Biodiesel from food crops (corn, sugarcane, raps, soybean ) Bioethanol from lignocellulosic and cellulosic biomass (straw, wood, grass ) Biodiesel/Bioethanol from Microalgae (CO 2 )

20 Cellulosic Ethanol with strong growth

21 Biofuel 2 nd generation

22 Process Milling Pretreatment ph ~ 1, > 160 C Enzymatic Process Fermentation Original 90% DW Original milled 90% DW After pretreatment 25% DW After liquification 12% DW

23 2 Step process Cellulose Enzymatic process Fermentable sugars Fermentation Bio ethanol

24 1 Step process: simultaneous saccharification & ferm. (SSF) Cellulose Enzymatic process Fermentable sugars Fermentation Bio ethanol

25 SSF with a standard microbial fermenter

26 Solid & liquid agitation

27 Wheat straw. 31.6% dry matter. Provided by Lund University, Department of Chemical Engineering, G. Zacchi / M. Galbe

29 ph control

30 Temperature control 2 Measuring points 2 1 Eucalyptus chips. 24.4% dry matter. Provided by Lund University, Department of Chemical Engineering, G. Zacchi / M. Galbe

31 Extract of specific functions: agitator Solid Phase Anaerobe fermentation Energy input Even nutrient, Enzyme & temp. distribution High Main function Low Low requirement but main funktion

32 Bioreactor applications Microbial Cell culture Biofuel 2 nd generation Biofuel 3 rd generation Syngas

33 Microalgea

34 Microalgea Photoautotrophic organisms complex organic compounds from simple substances: (carbohydrates, fats, and proteins)

35 Algae products

36 Biofuel 3 rd generation Challenges and reactor concepts Open pond Tubular reactors horizontal/ vertical Flat panel reactors horizontal/ vertical

37 Open ponds Extremely simple Low energy input High evaporation Need a lot of space Low algae concentration

38 Key target: high algae concentration Only with tubular or flat panel reactor concept

39 Tubular reactors Medium/high volumetric productivity Scale-up possible High energy input High investment costs

40 Flat panel reactors High volumetric efficiency Low energy input Medium investment costs Scale-up possible

41 The air lift principle Assymetric head space Reduction of foam Baffle Sparger

42 Sterility & PAT for reproducible high quality data

43 Laboratory scale photosynthesis Stirred tank Flat panel

44 Stirred tank Traditional technology, well established Used by many scientists Plenty of reference data Less light in the center Scale-up difficult Light On 115 mm

45 Why two different vessels? Stirred tank Pilot scale 1 m

46 Light intensity How much light is needed in the lab? Max. light intensity at noon 800 µmol/m²s (40%) 1400 µmol/m²s (70%) 2000 µmol/m²s 2000 µmol/m²s light inhibition 400 µmol/m²s often optimum µmol/m²s enough for growth 1400 µmol/m²s (70%) 800 µmol/m²s (40%)

47 Typical agitator functions (photo bioreactors) Open pond Tubular bioreactor Flat panel bioreactor Stirred tank bioreactor Even nutrient distribution By water wheel By pump By gassing Stirrer

48 Bioreactor applications Microbial Cell culture Biofuel 2 nd generation Biofuel 3 rd generation Syngas

49 Syngas fermentation Very specific requirements Toxic ATEX Low CO transfer into water Complex control strategies Very slow co-substrate feeding Solutions on the way

50 Thank you!

From Biomass. NREL Leads the Way. to Biofuels

From Biomass. NREL Leads the Way. to Biofuels From Biomass NREL Leads the Way to Biofuels The Wide World of Biofuels Fuel Source Benefits Maturity Grain/Sugar Ethanol Biodiesel Corn, sorghum, and sugarcane Vegetable oils, fats, and greases Produces