Design and installation of a next generation pilot scale fermentation system

Area of Science:

• Biotechnology and Biochemical Engineering
• Industrial Microbiology
• Process Control Systems

Background:

• Existing industrial research fermentation pilot plant designed in the early 1980s.
• Need for updated fermenter technology and control systems for enhanced bioprocesses.
• Requirement to balance modernization with compatibility with existing infrastructure.

Purpose of the Study:

• To design and construct four new fermenters for secondary metabolite cultivations, bioconversions, and enzyme production.
• To implement a new PC/PLC-based control system for improved process management.
• To integrate these new systems into an existing industrial research fermentation pilot plant.

Main Methods:

• Design and construction of four novel fermenters.
• Implementation of a new PC/PLC control system utilizing GE Fanuc PLCs, Genius I/O, and Fix Dynamics SCADA software.
• Integration of new systems into an existing pilot plant, focusing on hardware and software compatibility.
• Strategic material selection (e.g., Inconel) and piping layout for improved functionality and safety.

Main Results:

• Successful design and construction of new fermenters and control system.
• Enhanced capabilities for secondary metabolite, bioconversion, and enzyme production.
• Improvements in corrosion resistance, safety (hazardous energy isolation), and instrumentation flexibility.
• On-line calculation and control of nutrient feed rates for optimized bioprocesses.

Conclusions:

• The new fermenters and control system effectively enhance the capabilities of the industrial research fermentation pilot plant.
• The design successfully balances the integration of modern technology with the preservation of existing infrastructure.
• The implemented improvements offer greater efficiency, safety, and flexibility in bioprocess operations.