DE4006382A1 - Modules for construction of various biological reactors - has releasably fastened modules of different sorts for rapid assembly of reactors for development purposes - Google Patents

Abstract

Prefabricated modules for biological reactor development consisting of: A base flange module with provision for power input. A support module with inner diameter/height ratios D1-H1 of from 0.7-1.0. A flange adaptor with inside diameter D2 relief to suit insert. A temperature control module with inner diameter/height ratios D3-H3 of from 0.3 to 0.5 and a heating -cooling shroud. A reactor module with inner diameter/height ratios D4-H4 of from 0.12 to 0.5. and allowance insert. A lid module with further support module. All releasably fastened together to form a variety of closed systems with energy input options, prod. input and output and sensor positions etc.. Linings can be of alloy steel, special glasses, plastic and/or ceramic. USE/ADVANTAGE - Modular system for the constructione of biological reactors for development of diverse processes: e.g. aerobic, anaerobic, sterile, unsterile, continuous, discontinuous, with or without biomass fixing or with biomass feedback. (claimed). Prefabricated modules and adaptors give ease of system assembly and modification.

Description

Field of application of the invention

The invention relates to a bioreactor for carrying out Experiments, with the aim of developing microbiological Process on a laboratory and pilot plant scale, through its apparatus technical diversification to the microbiological process adapted technical bioreactors can be designed.

Characteristic of the known technical solutions

With conventional stirred reactors that are used for material conversion processes can be used in a range of bio primary requirements are met. The concerns a uniform distribution of the microorganisms and the nutrients over the entire cultivation volume, the Supply the biomass with nutrients and the setting certain milieu conditions (temperature, pH, pressure). Further requirements arising from typical bioprocess conditions result, are due to the design (preferably un Detachable connections of the reactor assemblies and the reactor form) no longer to be fulfilled.  

This includes the concentration of the biomass, the decoupling of residence time and biomass concentration, avoidance of Microorganism damage due to high shear forces in the area the stirring elements and the implementation of continuous processes. Another disadvantage is that the purchase and operation of stirring reactors are very expensive.

It is known that some of the resulting from the bioprocess Requirements from tower reactors and modes derived from them can be fulfilled. Advantageous properties these bioreactors are simple in construction, dispense with moving parts (stirrer), reduced space requirement, less Energy input, smaller heat transfer areas, implementation high material input rates, good transport coefficients, good ones Energy dissipation, lack of zones and extreme shear stress and varying the liquid phase dispersion to some extent Extent by constr. Activities.

The disadvantage, however, is that due to the design, design and manufacturing technology (mostly inseparable connection of the reactor assemblies) the adaptation of an existing bio reactor to changing process conditions not without major Effort is possible. Another disadvantage is that such Ent development trends in bioreactor technology such as development of continuous processes, especially of multi-stages processes, the further increase in the biomass concentration in the reak tor, the integration of processing steps, the coupling possibilities (material flows, energy flows) before and after switched process stages a safe scale-up and choice wise aerobic or anaerobic operation, without serious technical Interventions in the bioreactor configuration are inadequate or even impossible cannot be taken into account. All subsequent interventions fe in the bioreactor configuration and the bioprocess engineering optimal design of the reaction space are time consuming and expensive.

Aim of the invention

The aim of the invention is to create a simply constructed and easy-to-use bioreactor, which due to its construction, Configuration and manufacturing technology bioprocess engineering Offers opportunities that depend on a particular fabric system ongoing microbial processes regarding the design, Development and testing of microbial processes under seek as well as the transfer of the process into a technical Scale, time-saving and effective.

State the nature of the invention

The invention is based on the technical problem, one easy to use, universally applicable, in its geometry and bio-process engineering flexible bioreactor to develop that quickly, easily and in an optimal way to develop biotechnological process variants to be developed can be fitted.

This applies in particular to the development of continuous ongoing microbial processes, increasing the bio mass concentration in the bioreactor as well as the integration and Coupling of processing steps in or to the bioreactor. The microbial processes can be under aerobic or on aerobic conditions sterile or non-sterile in one or more Process stages run. The bio-process engineering design of the bioreactor ensures an even distribution of the micro organisms and nutrients over the entire cultivation volume, the adequate supply of the biomass with nutrients that Dissipation or supply of heat, dissipation of energy, high transport coefficients, variation of the liquid phases through mixing, defined management of material flows and the variation the diameter / height ratio allow a safe Scale-up.

According to the invention the object is achieved in that under different modules and adapters that are prefabricated and under can solve various bio-process engineering tasks by detachable connections are coupled together by flanges,  taking the order of each module and adapter is freely selectable and the number of individual modules and adapters can also be not equal to 1.

So is on a bottom flange module that in its middle part Connection for an energy flow entry (e.g. gas) or centrally has a stirrer, a nozzle module with an inside knife / height ratio (D1 / H1) from 0.7 to 1.0, which on its circumferential surface at opposite points has arranged. A flange adapter with an inside through knife D2, the inner ring surfaces of different brackets and recording systems for bioprocessing reactor built-in components (such as a counter bearing for a stirrer, for a or several pipes centrally located in the reactor Diameter, ring-shaped clamps for centrally arranged Membrane hoses or holding elements for centrally fixed disc-shaped carrier elements for the defined positioning of Microorganism growth materials) connects the Nozzle module with a temperature control module with an inner diameter / Height ratio (D3 / H3) from 0.3 to 0.5, this at its outer surface arranged in a known manner Has tempering jacket. A reactor is also flanged shot module with an inner diameter / height ratio (D4 / H4) from 0.12 to 0.5 the same as the flange adapter on one or two ring inner surfaces of its connecting flanges for Mounts and recording systems can have. Here are in particular mounts for such reactor internals (such as e.g. Holding elements for centrally fixed disc-shaped carriers elements for the defined positioning of microorganisms growth materials) that accommodate a fixed bed or a foam prevent education. The outer surface of the reactor section modules can be made of corrosion-resistant metal, special glass or Be made of plastic. A is attached to the reactor shot module Flanged nozzle module, the one provided with a nozzle Cover flange module is completed, so that a total closed reactor space arises in the usual way can be subjected to sterilization.  

The inner diameters D1, D2, D3 and D4 of each Modules can be different so that modules are the same Inner diameter connected to each other and with modules of one other inner diameter using constructively indicated Fitted flange adapter can be combined to thereby e.g. B. he changed flow conditions in the bioreactor possible.

However, the inner diameters are preferably D1, D2, D3 and D4 of the same size, while the heights H1, H2, H3 and H4 can be varied.

Surprisingly, it was found that the combination and coupling ability of the prefabricated modules with each other and the variance of the number and the bioprocess engineering Effect of individual modules, with certain inner diameters / heights ratio of bioreactor volume obtained in a wide variety of stages and several reactors coupled via connecting pipelines as well as new bio-process effects are induced can. The realities are simple and short Sation of such reactor combinations possible where in a reactor or by coupling several reactors via piping systems to several process stages or several corresponding micro developed, tested and integrated into a technical process Scale can be transferred. To ensure a uni vers combined ability of the prefabricated modules and Flange adapters with each other point the flanges of the socket modules, the temperature control module, the reactor shot module and the End faces of the flange adapter alternately tongue or groove on, which also in the cover flange and bottom flange are attached module.

Furthermore, it was found that using the step setting the reactor system, the dwell time of the material system is optimal Way to the microbiological process and the resulting sub stratstrom can be adjusted. It also emerged that for Bacteria that work together in nature (e.g. in the Nitrification Nitrosomonas and Nitrobucter or methane fermentation acid-forming bacteria, acetic acid-forming bacteria and methane-forming bacteria), by the arrangement of the reactor modules and the feeding of substrates and carbon sources  containing material flows at certain points in the reactor, Favorable living conditions for given defined reactor zones can be generated and maintained. It is also possible through the use of microorganism growth carriers in defi nated areas of the reactor, the residence time of decouple the microorganism density and concentration, and through the interconnection of substrate and product streams at mikro biological processes that take place in one or more stages, to increase the downtimes of fixed bed reactors and the out formation of typical concentration profiles for substrate and Avoid product.

It was also found that by fixing the micro organisms on different substrates and the arrangement the carrier materials by means of carrier material receiving devices at a certain distance from with a stirrer equipped bottom flange module, the damage to the microorganisms can be largely avoided by high shear forces and thus an outer loop for returning the exiting Liquid flow in the fixed bed entrance becomes superfluous. This can reduce concentration gradients, the pH profile leveled and an improvement in product release achieved will.

Embodiment

The bioreactor to be diversified according to the invention conducting experiments for development, testing and Scale transfer from to the microbiological process and Bioreactors adapted to the material system are intended below are explained in more detail using an exemplary embodiment the figure shows a representation of the bio according to the invention reactor for anaerobic wastewater treatment with the help of Carrier material immobilized microorganism populations in principle.  

The nozzle module 1 (D1 / H1 = 0.8) is placed on the bottom floor flange module 6 with feet and the nozzles a, b, which can be used for emptying or for gassing or for receiving gassing elements (rings, nozzles etc.). assembled. On the circumference of the nozzle module 1 , the nozzles c, g and d, h are arranged in pairs in a sectional plane.

The nozzles, to which pipes or hose connections can be connected flexibly or firmly in a certain diameter range, serve for the supply and discharge of the waste water and the addition and removal of inoculation sludge. Both modules are made of corrosion-resistant high-alloy steel. A flange adapter 2 with a diameter D2 connects the nozzle module 1 to the temperature control module 3 arranged above it (D3 / H3 = 0.37).

The coupling of the modules 1 and 3 is also without the flange adapter 2 , the inner ring surfaces of which incorporate different mounts and mounting systems for biologically active reactor z. B. pipes, membrane tubes, support elements for microorganism growth materials, etc. may be possible. The double jacket of the temperature control module 3 is used to hold the circulating heating and / or cooling medium. The temperature control module 3 also consists of high-alloy steel.

The reactor shot module 4 is arranged above the temperature control module 3 and screwed to it. The reactor glass module 4 , which is made of special glass and which, in conjunction with adapted clamping elements, can also have different heights H4 (600-1200 mm), serves to coat the microorganism growth carrier. The reactor section is made of special glass or plastic for visual control and observation of the ongoing microbial process. The reactor head, which consists of a further nozzle module 1 with a screwed-on cover flange module 5 , closes off the bioreactor chamber at the top. The nozzles l, m, e, f, i and k arranged in the cover flange module 5 and in the nozzle module 1 are used for discharging gases, supplying and discharging waste water, as an overflow and for receiving sensors. On the reactor internals 7 , the growth carrier materials were applied. The solids-relieving waste water, which is to be cleaned on a microbial basis under anaerobic conditions, reaches the bioreactor via the nozzles i, k in the head part (outflow) or the nozzles g, h in the bottom area (upstream). To reduce the temperature, pH and concentration gradients, the reactor contents are circulated with the help of a pump via an external piping system. The piping system arranged outside of the bioreactor is connected to the reaction space at the bottom via connection b and at the top via connection e. The outer pipe system is designed so that both the circulation of the reactor contents in the upstream or downstream is possible. Depending on the connection variant (upstream or downstream), the suction port of the pump is located on the lower or upper port module l. The vaccine sludge, in which the microorganisms required for microbiological cleaning are present in suspended form, is sucked into the outer pipeline system via a nozzle and mixed with the waste water is pumped into the reaction chamber and brought into contact with the carrier material provided for immobilization. The carrier materials were previously arranged in the area of the reactor shot module 4 on the reactor installation 7 . The heat required for the microbial process is given via the heating medium circulating in the double jacket of the temperature control modules 3 .

To ensure a constant reactor fill level, the same amount of wastewater as the amount of wastewater supplied leaves the reaction chamber via a siphon connected to nozzle g. The biogas resulting from the metabolic activity of the microorganism population leaves the reactor via the nozzle m in the cover flange module 5 . The biogas can be sucked off through a pipeline system equipped with a blower and can be pressed back into the reaction space via the connection piece d in the lower connection piece module l.

List of reference numbers

1 nozzle module
2 flange adapters
3 temperature control module
4 reactor shot module
5 cover flange module
6 bottom flange module
7 reactor internals
at the neck

Claims (2)

1. bioreactor for carrying out biotechnological process variants such. B. aerobic, anaerobic, sterile, non-sterile, continuous, discontinuous, with and without biomass fixation or with biomass recycling, consisting of a closed with an energy input system closed reaction vessel, the inner walls and internals made of alloy steel, special glass, plastic and / or kera mix material are made and which nozzle for a product supply and discharge as well as measuring points for the process management, characterized in that with each other through tongue and groove flanges a prefabricated ter bottom flange module ( 6 ) with devices for energy input, a prefabricated nozzle module ( 1 ) with an inner diameter / height ratio D1 / H1 of 0.7 to 1.0, which has on its outer surface at opposite points nozzle, a prefabricated flange adapter ( 2 ) with an inner diameter D2, the inner rings with recordings for Reactor internals ( 7 ) is provided, a pre-made r temperature control module ( 3 ) with an inner diameter / height ratio D3 / H3 of 0.3 to 0.5, this having on its outer lateral surface a heating and cooling jacket arranged in a known manner, a prefabricated reactor section module ( 4 ) with an inner diameter - / Höhenver ratio D4 / H4 from 0.12 to 0.5, the flange on the inner ring receptacles for reactor internals ( 7 ) have a prefabricated with flange cover flange module ( 5 ), which is coupled to a further nozzle module ( 1 ) , are releasably connected. 2. Bioreactor according to claim 1, characterized in that the order of the combination of the nozzle modules ( 1 ), temperature control modules ( 3 ), reactor shot modules ( 4 ) and flange adapter ( 2 ) can be selected as desired and the number of the respective modules and adapters is not equal to 1.