Professional Documents
Culture Documents
Bioprocess Engineering 2
Course Notes, Autumn 2014, Part 2 of 2
Dr Denise Croker, BM-028
Denise.Croker@ul.ie
Office Hours, Wednesday 11- 1.
6. HEAT TRANSFER
6. Heat Transfer
6.1 Heat transfer equipment
Two major applications of heat transfer (ht) equipment in bioprocessing, are for
bioreactor temperature control (usually removal of heat by cooling water), and for
the thermal sterilisation (by addition of heat using steam) of substrate media prior
to fermentation.
The rate (and hence efficiency) at which heat is transferred is primarily determined by
two key parameters:
1.
2.
Heat transfer
configurations for
bioreactors: (a) jacketed
vessel; (b) external coil;
(c) internal coil; (d)
baffle-type coil; (e)
external heat exchanger
(a) & (b): Dont interfere with mixing in vessel, easy to maintain sterility, but low HT area
only really suitable for small/lab-scale vessels.
(c) & (d): High HT area hence good for large reactors, but may have mixing, sterility,
and/or cleaning issues.
(e):
Excellent HT area, may have problems with sterility or pumping mechanical
shear degradation of cells. Heat exchanger residence time must be small in
aerobic fermentations to ensure minimal depletion of liquid phase oxygen.
From Bioprocess Engineering Principles by Pauline M. Doran
The variation of cooling water temperature with distance through the coil in internal coiltype HT equipment (c) and (d) can be seen below:
The coolant temperature rises as it passes through the coil and takes up heat, whereas
the fermenter temperature remains fairly constant since the contents are well mixed.
Countercurrent
Cocurrent
Shell and tube heat exchangers are used for HT area applications >15m2:
Shell and tube heat exchangers are used for HT area applications >15m2:
Shell and tube heat exchangers are used for HT area applications >15m2:
(93)
The rate of heat transfer by conduction through the pipe wall, Qw, can be obtained from
Fouriers law:
dT
Qw kA
(94)
dy
where k = wall thermal conductivity and y = distance from the hot side.
In this case, integrating eq. (94), with limits of: T=Thw at y=0, and T= Tcw at y=B gives:
Qw
kA
Thw Tcw kA Tw
B
B
Qw
(95)
Tw
Rw
(96)
Rw
B
kA
(97)
1
hh A
(98) and
Rc
1
hc A
(99)
When a system, such as our heat exchanger pipe, contains a number of different heat
transfer resistances in series (thermal boundary layers + pipe wall), the overall
resistance is equal to the sum of the individual resistances.
In eq. (100):
T
T
RT Rh Rw Rc
(100)
T Th Tc
RT
1
B
1
hh A kA hc A
or
RT
1 1 B 1 1
A hh k hc UA
Q UAT
(101)
(102)
Eq. (102) allows quantification of Q knowing U, A and with easily measureable hot and
cold bulk fluid temperatures.
From eq. (101) we can see that the major factors that govern the value of U are the
fluid hydrodynamics at the thermal boundary layers and the thermal conductivity and
thickness of the pipe wall.
U h fh hh k hc h fc
(103)
(102)
Calculation of the heat transfer area, A, required for a particular heat exchanger, from
eq. (102), requires that Q, T, and U are known. The former two may be obtained from
energy balance calculations, whilst U is estimated from empirical correlations based on
experimental data.
6.4.1 HT system design: energy balance calculations
For double pipe or shell and tube heat exchangers, the general energy balance
equation (83), under steady-state conditions and in the absence of shaft work,
becomes:
M i Et i M o Et o Q 0
(104)
When there is no heat lost by the heat exchanger, all heat removed from the hot stream
is transferred to the cold stream, thus Qh = Qc = Q , and:
M h Et hi Et ho M c Et co Et ci Q
(106)
If sensible heat only is exchanged between the fluids, then the enthalpy differences can
be given in terms of heat capacity, Cp, and temperature change:
(107)
Eq. (107) is used in heat exchanger design to determine Q and inlet and outlet
temperatures of the fluid streams. It can also be used to evaluate the heat removal
requirement from a bioreactor, to maintain a desired reactor temperature. In this case,
at steady state the temperature of the hot fluid (i.e. the fermenter broth) is constant, so
the left hand side of eq. (107) is zero, and:
(108)
Q in eq. (108) can be determined from the energy balance equation for cell bioreactors:
Q = -Hr
Mv.hv - Q + Ws
(92)
Use of the heat exchanger design eq. (102) requires knowledge of T, the difference in
temperature between the hot and cold heat exchange fluids. As we have seen however
in section 6.1, fluid temperatures, and thus the rate of heat exchange, vary with position
in heat exchangers, even under steady state operation. This problem may be resolved
by including temperature as a positional variable, and subsequently solving the coupled
differential design equations that result, or more often by the use of an average T.
When the temperature of both hot and cold fluids vary in either co- or countercurrent flow, the average taken is the logarithmic mean temperature difference (LMTD),
TL. In eq. (109) T1 and T2 are the
temperature differences between the hot and
T2 T1
L
the cold fluids at the ends of the exchanger.
(109)
ln( T2 / T1 )
These are calculated using the values of Thi,
Tho, Tci, and Tco from the energy balance eq. (108).
Assumptions made in eq. (109): U and Cps are constant; negligible heat loss; steady
state operation. Corrections must be applied to eq. (109) for multi-pass exchangers.
When one fluid remains at constant temperature, e.g. in fermenters, the arithmetic
mean temperature difference, TA is used. In
eq. (110), TF is the fermenter temperature, and
2TF (T1 T2 ) (110)
T1 and T2 are the inlet and exit temperatures of
TA
2
the heat exchange fluid.
U h fh hh k hc h fc
(103)
The wall resistance term can be calculated knowing the thickness (B) and thermal
conductivity (k) of the wall material. Fouling factors (hfh and hfc) (if applicable) can be
estimated from typical literature data, as already seen.
Determination of the thermal boundary layer HT coefficients (hh and hc) is more
problematic however, since they are dependent on flow hydrodynamics and fluid
properties adjacent to the wall surfaces. These are normally evaluated using
experimentally determined empirical correlations, expressed in terms of dimensionless
numbers. This is similar to the situation for liquid-solid (external) mass transfer
coefficients (see section 4.3.1).
The Nusselt number, Nu, is the primary means by which hh or hc is calculated:
This dimensionless number represents the ratio of
hD
convective to conductive heat transfer rates.
Nu
k fb
where D = pipe or tank diameter and kfb =bulk fluid thermal conductivity.
(111)
Many empirical correlations exist that allow the determination of the Nu for different
heat exchange situations. These involve other, experimentally-measureable
dimensionless numbers or physical parameters, including:
Pipe Reynolds number, Re
Du
(112)
b
N i Di2
C p b
k fb
(113)
(114)
(115)
when 104 Re 1.2 x 105 and 0.7 Pr 120 and L/D 60.
Nu 0.027 Re 0.8 Pr 0.33 b
w
0.14
(116)
(117)
Remax = Re with D = outside pipe diameter and u = maximum linear flow velocity
through the pipe bundle. C = 0.33 for staggered and C = 0.26 for in-line tubes.
Stirred tanks:
0.62
0.33 b
Nu 0.87 Rei Pr
w
Helical coil hx
0.14
(118)
0.62
0.33 b
Nu 0.36 Rei Pr
w
Jacket hx
0.14
(119)
7. DOWNSTREAM
SEPARATION PROCESS - 2
Post Reaction/Fermentation
Steps
31
Unit operation
Regular filtration
Cell isolation
Centrifugation
Cell disruption
Microfiltration/ultrafiltration
Dialysis/reverse osmosis
Liquid-liquid extraction
Adsorption
Chromatography
Final purification
Crystallisation
Final purification
Drying
34
http://www.halwachs.de/solvent-extraction.htm
http://www.cheresources.com/liquid_extractor_design5.gif
35
Product
Extractive solvent
Antibiotics
Penicillin
Erythromycin
Steroids
Vitamins
Vitamin B12
Isopropanol
Alkaloids
Morphine
Codeine
Butanol or benzene
Trichloroethylene
Organic solvents are not suitable however for the isolation of proteins and other
sensitive biopolymers, since denaturation can occur.
36
37
38
From Bioprocess Engineering Principles by Pauline M. Doran
39
[i ]L
[i ]H
(17)
If K>1, then component i favours the light phase, and vice versa.
In many systems K is constant over a wide range of solute concentrations, provided
that the molecular nature of the solvent phases are not changed. There are many
factors that determine the value of K for a particular system, including:
Size, electric charge, and hydrophobicity of the solute molecules/particles
Biospecific affinity of the solute for one of the solvent phases
Surface free energy and ionic composition of the solvent phases
For these reasons it is not possible to predict K from molecular properties. In some
cases it is possible to produce an empirical correlation (from lab-scale experiments)
that allows quantification of K for a particular system.
40
For example for extraction of soluble proteins with some polyethylene glycol (PEG)
containing aqueous two phase systems, the following empirical correlation can be
used:
K e
A. M
T
(18)
YL
and:
VL
V
VL H
K
YH
VH
VL K VH
Partition coefficient
increases with
potassium phosphate conc. ,
resulting in
more efficient separation of
enzyme A
42
From Bioprocess Engineering by M. L. Shuler & F. Kargi
[i ]L
c
[i ]o
[i ]H
[i ]o
In the PEG-salt two phase aqueous system, proteins can be effectively separated from
cell debris, with the proteins partitioning into the light phase and the debris into the
heavy phase. It is only usually necessary to use a single mixer-settler stage since the
partition coefficient, K, is high for this system.
In many cases however phase separation equilibrium is not achieved in a single stage
and multistage operation is required.
43
44
45
http://www.halwachs.de/mixersettler.gif
46
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47
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48
(a)
(b)
(c)
(d)
(a) Oldshue-Rushton extractor; (b) Scheibel-York extractor ; (c) Rotating-disk extractor ; (d) Pulsed extractor
49
http://accessscience.proxy.mpcc.edu/content.aspx?id=636100
http://images.vertmarkets.com/crlive/files/Images/92F9B851-C50C-11D3-9A8200A0C9C83AFB/pod2.jpg
51
7.2 Adsorption
This involves the concentration of component(s) of a fluid phase (in bioprocessing,
usually a liquid) on the surface or in the pores of a solid adsorbent material. The
adsorbed fluid component is called the adsorbate.
52
Step 2
A-free liquid
Adsorption
site
Catalyst pore
Adsorbent pellet
cross-section
Step 1
Adsorbent surface
stagnant liquid film
(external boundary layer)
A (liq)
Step 3
A (ads)
Mass transfer and adsorption steps during adsorption of a liquid phase adsorbate, A
53
Mass transfer (external diffusion) of adsorbate from the bulk fluid to the
external surface of the adsorbent pellet
2.
3.
4.
5.
6.
External diffusion of concentrated adsorbate from the pellet surface into the bulk
fluid
54
Adsorbents
High surface area porous materials. Typical surface areas: 1 to 1000 m2/g.
\\\\\\
Styrene
DVB
Acrylamide
55
Applications in bioprocessing
Ion exchange adsorption is widely used for the recovery from fermentation
broths of: amino acids, proteins, antibiotics, and vitamins.
Adsorption generally has higher removal selectivity but smaller removal capacity
than liquid-liquid extraction methods.
56
Industrial Adsorption
Operation steps
1.
2.
3.
4.
5.
Equipment types
Adsorption operations are normally carried out in fixed, packed adsorbent beds.
Other equipment types sometimes found include moving beds, fluidised beds and
stirred-tank contactors.
57
58
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Quantification of Adsorption
Adsorption/desorption is an equilibrium process and the extent of adsorption of a
component on a solid surface is determined by the adsorption equilibrium
relationship. Since a number of different driving forces and types of adsorption may
be involved in a given adsorbate-adsorbent system, no single quantification model is
universally applicable.
*
AS
C ASm K AC A*
1 K AC A*
(23)
where: C*AS is the amount adsorbed per unit adsorbent, CASm is the maximum
amount adsorbed giving compete coverage of all adsorption sites with monolayer
coverage, C*A is the equilibrium concentration of adsorbate in the fluid phase, and
59 KA
is a constant.
Langmuir isotherm:
*
AS
C ASm K AC A*
1 K AC A*
Freundlich isotherm:
*
AS
KFC
*1
n
A
60
From Bioprocess Engineering Principles by Pauline M. Doran
For liquid-solid systems, the Freundlich isotherm has been found to be more
applicable:
*1
*
C AS K F C A n
(24)
where KF and n are constants for a particular system. If adsorption is favourable n >1
and vice versa.
This adsorption isotherm applies well for the adsorption of many antibiotics,
hormones, and steroids.
There are many other adsorption isotherms, each applicable only to certain systems.
Since the exact adsorption mechanisms vary from system to system, adsorption data
cannot generally be predicted from theory, but must be determined by laboratory
experiment.
61
The mixture containing the solute is continuously passed through the bed and
amount adsorbed increases with time.
Eventually the bed becomes fully loaded/saturated.
Desorption of concentrated solute is carried out.
Regeneration of the adsorbent is performed, prior to restarting the cycle.
When step 2 occurs, the unadsorbed solute breaks through the adsorbed bed, as
observed by an increase in the effluent solute concentration.
62
63
From Bioprocess Engineering Principles by Pauline M. Doran
The mixture containing the solute is continuously passed through the bed and
amount adsorbed increases with time.
Eventually the bed becomes fully loaded/saturated.
Desorption of concentrated solute is carried out.
Regeneration of the adsorbent is performed, prior to restarting the cycle.
When step 2 occurs, the unadsorbed solute breaks through the adsorbed bed, as
observed by an increase in the effluent solute concentration.
Efficient operation of a fixed bed adsorber is greatly dependent on the shape of the
breakthrough curve and on the exact effluent solute concentration at which
adsorption operation is stopped:
Waiting until high effluent solute concentrations are reached means losing a
large amount of solute unadsorbed.
65
From Bioprocess Engineering
Principles by Pauline M. Doran
66
67
From Bioprocess Engineering
Principles by Pauline M. Doran
Precipitation
In bioprocessing, there are three major methods used for precipitation.
1. Salting out by adding inorganic salts such as sodium sulphate at high ionic
strength. The added ions interact with the water more strongly, causing the
protein molecules to precipitate. The relationship between protein solubility, S,
and solution ionic strength, I, can be given by:
log
S
K S .I
So
(25)
I 0.5[i].Zi2
71
72
log
S
K
2
So
Ds
(26)
73
74
http://upload.wikimedia.org/wikipedia/commons/7/7e/Lysine_pI.png
75
Supersaturation
Saturated Solution
Supersaturated
The amount of solute dissolved
in the solution is greater than
the solubility
Undersaturated
Generating Supersaturation
Supersaturation
No Nucleation
But
Growth is Possible
No Nucleation
No Growth
82
83
84
Crystal face
Bulk solution
cb
cb - ci
Concentration
ci
ci - cs
cs
85
7.8.2.2
86
(27)
(28)
87
(29)
88
Solubility
MX (anhydrous salt)
NaCl
KNO3
Temperature
89
Batch crystallisation
These most often take the form of an open tank with agitation, heating/cooling and
evaporation at the free surface. Agitation helps ensure uniform crystal size
distribution. The major difficulty with this type of unit is fouling of the heat exchange
surfaces by product crystals.
91
End view
Votator crystalliser
92
From: Chemical Engineering, vol. 2 Coulson & Richardson, p673-681
Votator crystalliser
93
http://www.labx.com/v2/adsearch/morepics.cfm?chpics=1&chback=
1&adzone=431000&pic=431030&cn=0&adnumber=431030
Supersaturation
Nucleation &
growth
94
Vacuum
Supersaturation
Nucleation &
growth
95
Cell concentration:
Substrate concentration:
Product concentration:
dV
F
dt
(120)
dx
(121)
x( D)
dt
ds
qP
D si s
mS x
dt
YXS YPS
dp
q p x pD
dt
Fed batch
bioreactor
(122)
(123)
M x M x,o (YXS si F )t fb
(124)
where Mx,o = cell mass at start of substrate feeding and tfb = time from start of feeding
Reactor substrate concentration:
s0
(125)
Product concentration:
p YPSsi
(126)
* Quasi-steady state operation involves operating the reactor in batch mode until a
high cell density is achieved and where substrate is virtually exhausted, and then
commencing substrate feeding. Under such conditions the large cell mass present
ensures that the substrate is consumed as fast as it is supplied in the feed, hence
giving s 0.
Dsi s
Substrate concentration:
max s
Km s
(127)
DK S
max D
x
Cell concentration:
Product concentration:
(128)
p pi
qp x
D
Dsi s
qp
D
ms
YXS YPS
(129)
(130)
x si s YXS
(131)
The critical dilution rate condition, Dcrit, for cell washout can now be obtained by
substituting from eq. (128) for s, letting x = 0, and solving for D:
Dcrit
Usually Ks << si , so Dcrit max.
max si
K S si
(132)
Biomass productivity, Qx, of a chemostat is the rate at which cells leave the reactor:
Qx
Fx
Dx
V
(133)
Substituting for x from eq. (129), again assuming no product formation or maintenance
requirement, gives:
DK S
YXS
Qx D si
max D
(134)
Dopt
The value of D for maximum Qx, Dopt, can be obtained by differentiating eq. (134) with
respect to D and equating to zero:
KS
Dopt max 1
(135)
K S si
No product formation
No maintenance requirement
T xim
xS
Fsi Fs
or
xs
YXS
Dsi s
YXS
T xim
YXS
V 0
xS T xim
(138)
(139)
(137)
Combining eqs. (137) and (139) and substituting the Monod equation (3) for gives:
max s
KS s
Dsi s YXS
si s YXS T xim
(140)
Immobilised cell
chemostat
ds T max s A
(141)
dz
Km s F
Plug flow
bioreactor with
immobilised
enzyme packing
Unsuitable for processes that evolve large amounts of gas, e.g. CO2, since gas
bubbles can become trapped in bed.
Heterogeneous flow
in a bubble column
Airlift reactors
Airlift reactors:
(a) and (b) internal
loop vessels,
and (c) external loop
Airlift reactors also do not require mechanical agitation for mixing and aeration:
Liquid flow pattern more defined c.f. bubble column reactor since there is physical
separation of the up-flowing and down-flowing streams.
(143)
Very large capacity (>1000m3 volume) airlift reactors have been built. Very tall
vessels (aspect ratios up to 100:1), called deep-shaft reactors have been built
underground. These have very good gas-liquid mass transfer.
Used for single cell protein production from methanol and gas oil, for plant and
animal cell culture, and in municipal/industrial waste treatment.
Upward flow of liquid through a particulate biocatalyst bed is the basis of operation.
treatment.
From Bioprocess Engineering Principles by Pauline M. Doran
8.2 Scale-up
Overview of a complex and evolving field
From our discussions thus far, it is obvious that biochemical processes can involve
numerous mass transfer and biochemical reaction steps, depending on their exact
nature.
Whereas the latter (biochemical reaction) steps are intrinsically independent of
the scale of the process, mass transfer steps by their very nature, are very sensitive to
the physical scale and hydrodynamic environment of the process.
For these reasons, scale-up of a biochemical or chemical reaction is often a complex
and demanding task, yet one that is critical to the commercial success of any process.
Treatment of this topic in textbooks and the process engineering literature is often
limited, focussing on relatively isolated cases, with the lack of a comprehensive
overview of scale-up methods and their ranges of application. In part, this may be due
to the fact that scale-up methodologies are currently in the process of undergoing a
major evolution, with the advent of computational fluid dynamics (CFD) applied to
reaction systems.
This section attempts to give my overview of the field as it stands at the time of writing.
Used for
Requires
Good points
Bad points
Reactions in
low viscosity,
well mixed
media.
Throughput,
yield, and
reaction time or
space time (V/F).
Simple method.
Ideal reactor
design equations.
Reactions in
low viscosity,
well mixed
media.
Throughput and
reaction kinetic
data. i if
immobilised
/catalyst.
Accurate method.
Can be used for
various reaction
conditions.
Scale-up based
on empirical
mass transfer
correlations.
Multiphase
reactions or
high viscosity,
poorly mixed
media.
Throughput,
medium rheology,
and empirical
mass transfer
correlation.
Relatively simple
to use.
Unreliable if reaction
conditions other than those of
the original mass transfer
correlation are chosen.
Non-ideal reactor
models.
Any type of
reaction.
Throughput,
medium rheology,
and reaction
kinetic data.
Powerful,
accurate method.
Works for
multiphase or
poorly mixed,
viscous reaction
media
Mixing time, tm
Ni.tm, Dimensionless
Mixing Time,
Typical scenario:
Given a mixing time Rei
correlation: estimate one
of V, Di, Ni, or tm, from the
equation, given values for
the other three.
( Ni tm )min
1.54V
at high Rei
Di3
(144)
ND 2 N 2 D DT W H
Np
f
,
,
,
,
,
.....
etc
N 3D5
g
D
D
D
(145)
where the first and second terms inside the brackets are the Reynolds and Froude
numbers respectively, and the latter three terms are associated with vessel geometry:
D = impeller diameter, DT = tank diameter, W = baffle width, and H = tank height.
(146)
A simple power law function is often used to quantify this function, f*:
Np = K' . Reia . Frb
(147)
where the values of K', a, and b must be determined by experiment and curve fitting.
Method needs: lab/pilot reactor physical dimensions, stirrer speed and power
consumption, viscosity/rheology data, medium density.
2u 2u 2u (148)
u
u
u
u
P
u v w g x
2 2 2
x
y
z
x
y
z
t
x
2v 2v 2v
v
v
v
v
P
u v w g y
2 2 2 (149)
x
y
z
y
y
z
t
x
2w 2w 2w
w
w
w
w
P
u
v
w g z
2 2 2 (150)
x
y
z
z
y
z
t
x
where:
= density
t = time
x, y, and z are distance
u, v, and w are linear flow rates in the x, y, and z directions respectively
g = gravitational constant
P = pressure
= viscosity.
Determination of the reactor chemical property parameters requires the use of the ideal
reactor design algorithm (mole balance, energy balance, kinetics, stoichiometry, etc.,)
on a localised basis for different regions within the reactor, each of which is assumed
to be ideally mixed, but with different space time values.
Sequential solution of the Navier-Stokes equations and the reactor design algorithms
gives, on convergence, a detailed quantitative picture of mixing within the reactor and
allows prediction of non-ideal reactor conversion and product distribution.
Example of application of a CFD method (from PhD project of Dan Lane, UL)
A computational fluid dynamics (CFD) package such as FLUENT is used to
build a physical simulation model of the reactor.
An advanced reaction engineering package such as gPROMS Multizonal is
used to construct a chemical simulation model of the different mixing zones
within the reactor.
Both packages are then used sequentially and if necessary, iteratively, to
solve the Navier-Stokes equations (FLUENT) and the reactor design
algorithms (gPROMS) for a given set of operating conditions.
Reaction
kinetics
Rheology
data
gPROMS
Multizonal
CFD (FLUENT):
Navier-Stokes eqns
Outflow
External recycle
Tank
volume
1362
m3
Direction of
rotation
Velocity decreases
45
ideal
non-ideal
240
Caustic (g/L)
50
40
35
30
230
220
25
20
210
0
200
400
600
800
1000
200
Time (mins)
600
800
1000
Time (mins)
4.0
30
3.5
25
3.0
Sodalite (g/L)
400
2.5
2.0
1.5
1.0
20
950m3 of 1362m3
tank used
15
10
~31% of tank
not used!
0.5
0.0
0
0
200
400
600
Time (mins)
800
1000
200
400
600
Time (mins)
800
1000