Professional Documents
Culture Documents
Bi0pr0cessEngineering
9 Springer-Verlag 1992
kg/m" s
kg/m 3
Liquid viscosity
Liquid density
1 Introduction
Bioprocesses are usually developed in three stages or scales:
(1) Bench or laboratory scale, where basic screening procedures are carried out; (2) pilot plant, where the optimal
operating conditions are ascertained; and (3) plant scale,
where the process is brought to economic fruition. Scale-up
means reproducing in plant-scale equipment the results from
a successful fermentation made in laboratory- or pilot-scale
equipment [1]. The scale-up process thus directly influences
the production capacity and efficiency of a bioprocess.
2 Criteria of scale-up
List of symbols
a
m2/m 3
Cz
mole/m 3
C*
mole/m 3
Di
DT
HL
kL
N
mole/m 3 - atm
m/s
1/s
N,
OTR
mole/s - m 3
Pg
Po
pg
Q
kW
kW
atm
m3/s
Re i
TQ
V
vs
Joule
m3
m/s
50
Reactor geometry;
volumetric oxygen transfer coefficient, k L a;
maximum shear;
power input per unit volume of liquid, Po/ld
volumetric gas flow rate per unit volume of liquid,
O / v or V V M ;
superficial gas velocity, v~;
mixing time;
impeller Reynolds number, Rei= ~ ND~/#, and
momentum factor.
To combat the problems of poor mixing in large fermentors, especially with viscous non-Newtonian systems, Fox
and Gex [4] proposed to employ equal mixing times in fermentors of different" scales. Although important for fast
chemical reactions, the requirement of constant mixing time
is unnecessary for normal fermentations involving slow biological reactions. Furthermore, it has been shown that the
volumetric power input required to maintain equal mixing
time increases as the 2/3-th power of the system volume [5]
and can become prohibitive on scale-up. Experience proves
that the power input thus determined is much more than
required for practical scale-up. A reduction of the volumetric
power input with the increasing system scale in actual practice has been confirmed in a survey of European fermentation plants [6]. Criteria 8 and 9, suggested by Rushton [7]
and Blakebrough and Sambamurthy [8] respectively, have
not generally worked for fermentations. One main reason is
that no consideration is given to the effect of aeration on the
process results. Consequently, only criteria 1 - 6 are commonly considered for scale-up of bioreactors.
Criterion 1 is based on the fact that almost all of the
existent empirical or semi-empirical correlations for scale-up
are developed experimentally with geometrically similar reactors of different scales. When translating experimental results between reactors with different geometries, one needs
to consider the validity of correlations chosen from the literature and the necessity of developing or modifying the correlations for the special situation. For nongeometric scale-up,
a range of DI/DT, the ratio of impeller diameter to fermentor
diameter, capable of delivering acceptably good gas dispersion has been suggested by Oldshue [14].
The ultimate performance of most aerobic fermentations
is often oxygen limited. To ensure equal oxygen transfer rates
at various scales of operation, scale-up of aerobic fermentations is most commonly conducted with the criterion of
constant k L a. Criterion 3 is of critical importance to fermentations of shear-sensitive organisms. For example, mycelial
fermentations have been found to be affected by shear or the
absolute value of the impeller tip speed [9].
Equal power per unit liquid volume (Po/V) has been used
in many antibiotic fermentations as the primary scale-up
parameter. Typically, a Po/V value of 1.0 to 2.0 kW/m 3 is
used [10, 11]. It has been found to be the most successful
The reason that strong emphasis has been put on maintaining constant volumetric oxygen transfer coefficient, k z a, in
process scale-up is to ensure the same oxygen supply rate to
satisfy the oxygen demand of the desired cell population.
However, the oxygen transfer rate in a typical submerged
aerobic fermentor is actually the product of k z a and
(C*-CL); the latter represents the difference between the
equilibrium concentration at gas/liquid interface and the
dissolved oxygen concentration in bulk liquid phase. The
maximum oxygen transfer rate per unit volume (OTRmax) is
achieved when C L-~ 0: all oxygen entering the bulk solution
is rapidly consumed, i.e.,
OTRma x = k L a C*
(1)
51
Instead of the constant oxygen transfer coefficient (k z a),
a more meaningful scale-up criterion for aerobic fermentations is the constant oxygen transfer rate per unit volume at
a predetermined value of CL. For many microbial fermentations, this value of CL can be reasonably set as zero because
of the very low critical oxygen concentrations of the microorganisms such as yeast, Escherichia coli, Pseudomonas
denitrificans, etc. [17]. Equal maximum oxygen transfer rate
is the scale-up criterion suggested for these fermentations. In
other cases, the optimal values of CL have to be determined
in the bench-scale study.
In this work, improved scale-up strategies for aerobic
fermentations are proposed to be developed by keeping constant oxygen transfer rate, at the predetermined value of CL,
in different scales of operation through the use of different
oxygen partial pressures in influent gas streams. The gasphase oxygen partial pressure, pg, regulates C* via Henry's
law, i.e.,
(2)
C* = H L pg ,
V -~
(3)
52
Q
]Q
~s=(N/~
l\Ns,12'5 (~z_~)Dt,23.21(gssV/)-2"5 = 103"21 "
The ratio of superficial gas velocity is thus:
v.,., =
v~,, \ Q , ] \ D , , J
(Note: vs.~should also be evaluated to determine whether it is so high
as to cause impeller overloading or liquid blow-out in the large-scale
fermentor.) Accordingly, the ratio of gas-phase oxygen partial pressure, given in Eq. (5), can be calculated as:
P~
Po,s
Appendix
Determination of the ratio of gas-phase oxygen partial pressures
employed in different scales of fermentation for successful scale-up.
Example 1
It is assumed desirable to scale up a bioprocess from results obtained in a 10-1 vessel to a 10,000-1 fermentor based on the following
combination of scale-up criteria:
1. Geometric similarity, i.e.,
D~,t DTI
=
Q, = __v, =
Qs v~
1o
and
(V/~ 1/3
=
Example 2
(Q, (o,42=1o
=1o,
v,,~ \ Q J \O,,,]
where subscripts l and s represents large- and small-scale, respectively.
Di's
0.1 .
Ns D~,~
3. Empirical power input per unit volume suggested by Einsele [6],
i.e.,
(Pg/V)I (V/~- ~
(e./v)~, = \ v d
= 10-1"11 .
(4)
= (101"944 1 0 - 3 ) -0.77 (10) -0.67 = 1 . 3 9 .
(kL a)s
p,,,
(kL a),
-0.67
L(v./v)J
'
(5)
(vs)~
/p,o2 ND~\ ~
where Po is the nongassed power input and can be estimated from
the following relationship for geometrically similar vessels [7]:
when
References
Po ~ N3 D~
(7)
53
18. Taguchi, H.; Miyamoto, S.: Power requirement in non-Newtonian fermentation broth. Biotechnol. Bioeng. 8 (1966) 43-54
19. Niitsu, H.; Fujita, M.; Terui, G.: Tryptophan fermentation with
an improved strain of Hansenula anomala under the control
of dissolved oxygen concentration. J. Ferm. Teehnol. 47 (1969)
194-202
20. Sumino, Y.; Kanzaki, T.; Fukuda, H.: Oxygen transfer in L-glutamic acid fermentation by an oleic acid-requiring organism. II.
Effects of dissolved oxygen. J. Ferm. Technol. 46 (1968) 10401047
21. Connolly, J. R.; Winter, R. L.: Approaches to mixing operation
scale-up. Chem. Eng. Prog. 65(8)(1969) 70-78
22. Fukuda, H.; Sumino, Y.; Kansaki, T.: Scale-up of fermentors.
I. Modified equations for volumetric oxygen transfer coefficient.
J. Ferment. Tech. (Japan) 46 (1968) 829-837
23. Fukuda, H.; Sumino, Y.; Kansaki, T.: Scale-up of fermentors.
II. Modified equations for power requirement. J. Ferment. Teeh.
(Japan) 46 (1968) 838-845
24. Michel, B. J.; Miller, S. A.: Power requirements of gas-liqnid
systems. AIChE Journal 8 (1962) 262-266
Received October 16, 1991