Hrs/Week Total Hrs

: 04 Hrs. : 60 Hrs.

11BBC22 BIOREACTOR PLANT DESIGN IA Marks : 50 Exam Marks : 100

UNIT I: INTRODUCTION: Bioprocess definition, objectives, Material and energy balance involved in general bioprocess technology (Both steady state and Unsteady state) and all Upstream and Downstream process. Media formulation, seed culture and inoculum development, culture cell banks, Process Flow diagrams development. UNIT II: BIOPROCESS EQUIPMENT DESIGN: Operational models of reactors, - Batch, continuous, Fed Batch, repetitive batch, recycle and continuous cultivation; Novel bioreactors- Stirred tank, Air lift & Loop reactors, fluidized bed reactor, Packed bed and Hollow fiber membrane bioreactors, immobilized Bioreactor, Bioreactors for waste treatment processes; SSF bioreactors. Selection of bioprocess equipment (upstream and downstream). Mechanical design of reactors, heat transfer and mass transfer equipments. UNIT III: BIORECTOR ACCESSORIES: Basic design and construction of fermenters and its auxiliaries, Material of construction. Vessels for Bioprocess Vessel geometry and vessel design, bearing assemblies, Motor drives, Aseptic seals, Flow measuring and control devices, Agitator and Sparger Design, Sensors, piping and valves, Pressure relief system. Conveyers and elevator, control system and stability of control system. UNIT IV: MECHANICAL ASPECTS OF BIOPROCESS PLANT DESIGN: Reactor configuration, Facility design aspects; Utility supply aspects; Equipment cleaning aspects. Design considerations for maintaining sterility of process streams and process equipment; Piping and instrumentation; Materials of construction for bioprocess plants. UNIT V: OPERATIONAL REQUIREMENTS: Medium formulation and requirements for fermentation processes examples of simple and complex media, Inoculation process, sampling process, cell harvesting, Primary packing and secondary packing, waste disposable technology, Cooling of fermentor system, water system for bioprocess industry (water pretreatment, multimedia filteration, water softening, UV and RO purification), environmental aspects. Batch and continuous heat sterilization of Liquid media; Filter sterilization of liquids, Air sterilization-Techniques involved, sterility test and integrity test. Validation- structure, resources for validation, validation of systems and processes including SIP and CIP, cGMP guidelines. UNIT VI: TRANSPORT PHENOMENA IN BIOREACTORS: Mass transfer in heterogeneous biochemical reaction systems; Oxygen transfer in submerged fermentation processes; Oxygen uptake rates and determination of oxygen transfer coefficients (kLa); role of aeration and agitation in oxygen transfer. Heat transfer processes in biological systems. Numerical using Reynolds, Prandtls, Chilton & Colburn analogies. UNIT VII: SCALE UP OPERATIONS: Scale up and scale down issues, Effect of scale up on oxygenation, mixing, sterilization, pH, temperature, inoculum development, nutrient availability and supply; Bioreactor scale-up based on constant power consumption per volume, mixing time, impeller tip speed (shear), mass transfer coefficients. Scale up of downstream processes: Adsorption; (LUB method); Extractors (geometry based rules); Filtration (cross flow filtration, TFF) Chromatography (constant resolution etc.); Centrifugation (equivalent times etc.). Scale-down related aspects. UNIT VIII: EQUIPMENT DESIGN USING CAED: Detailed process and mechanical design of the following equipments Agitated and jacketed vessels, fermentor vessels, shell and tube heat exchanger and double pipe heat exchanger. Types of joints (welded), pipe and pipe fittings.

TEXT/REFERENCE BOOKS 1. Bailey and Ollis, Biochemical Engineering Fundamentals, Prentice Hall, 1992 2. Karl Schuler, Bioreaction Engg (Volume -1) John Wily (1987) 3. T. K Ghose (Ed) Process computation in Biotechnology, Tata Mc-Graw Hill, (1994) 4. Atkinson, B. & Maviuna, F. Biochemical Engg. and Biotechnology Handbook, Mc-Graw hill (2nd Edition, 1993) 5. H.J. Rehm and G. Reed (Ed) Biotechnology (Vol. 3, Biprocessing) VCH (1993). 6. W.R.Vieth et al., Design and Analysis of Immobilised Enzyme Flow Reactors. 7. M. L. Schuler & F. Kargi, Basic concepts Bioprocess Engineering - by Entice Hall 1992. 8. Pauline M. Doran, Bioprocess Engineering Principles, Academic Press 1995. 9. H. C. Vogel & C. L. Todaro, Fermentation & Biochemical Engineering Hand Book (1983), Principles, Process Design and Equipment. 10. Principal of Microbe & Cell Cultivation (1975), S J Print, Blackwell Scientific co.). 11. Peter, Max S. and Timmerhaus, Klaus D., Plant Design and Economics for Chemical Engineers, 4th ed., McGraw Hill, 1991. 12. Butterworth-Heiemann, A compendium of Good Practices in Biotechnology, BIOTOL Series, 1993 13. Seiler, Jiing P. Good Laboratory Practice: The why and How? Springer, 2001 14. Lydersen, B.K. et al., Bioprocess Engineering: Systems, equipment and facilities, John-Wiley, 1994