BASIC DESIGN AND

OPERATION OF
FERMENTER
M.Sc. MICROBILOGY 3RD SEM

DEPARTMENT OF MICRBIOLOGY
H.P.U

SUBMITTED TO : Dr. Prachi Vaid

SUBMITTED BY : Neha Sandhu
 INTRODUCTION
An apparatus that maintains optimal
conditions for the growth of microorganisms,
used in large-scale fermentation and in the
commercial production of antibiotics ,
hormones and other products is called an
FERMENTER OR BIOREACTOR
 HISTORY
First fermenter was designed by Chaim Weizmann
and team during first world war to produce acetone
using Clostridium acetobutylicum in 1914 to 1918
First true large scale aerobic fermenter was used in
central Europe in 1930 for production of compressed
yeast
Gradually advancements were made in the fermenters
Now a days full automatic fermenters and
bioreactors are available
 IDEAL FERMEMTER
The vessel should be capable of being operated
aseptically
Adequate agitation and aeration should be
provided
Power consumption should be low
Temperature and pH control should be there
Minimal use of labour
Vessel should be suitable for wide range of
processes
 CONTRUCTION MATERIAL
Glass vessel:
Glass vessels are smooth which makes it non toxic,
corrosion proof. It also makes it easy to examine the
interior of the vessel.
They are not appropriate for the large scale as there is
risk of handling
Stainless steel vessel:
Stainless steel is the most satisfactory material for large
scale fermentations. These vessels can be sterilized in situ
and hence have the capability to withstand pressure and
corrosion. Corrosion resistance can be improved by
tungsten, silicone and other elements.
 VARIOUS PARTS OF FERMENTER
PARTS APPLICATIONS
THE AGITATOR ( IMPELLOR ) 1) Agitator helps in providing the
growing cells with oxygen
2) Bulk fluid and gas phase mixing
3) Air dispersion
TYPES 4) Oxygen transfer
1) Disc turbines 5) Heat transfer
2) Vaned discs 6) Suspension of solid particles and
3) Variable pitch Open turbines maintain uniform position
4) Propellers
TYPES DIAGRAMS

DISC TURBINE : Consist of a disc with series of

rectangular vanes set in vertical plane around the
circumference

VANED DISC : has a series of rectangular vanes

attached vertically to underside

VARIABLE PITCH AND OPEN TURBINES : blades are

directly attached to a boss on the agitator shaft

PROPELLERS : mostly same as variable pitch open

turbines
MODERN AGITATORS DIAGRAM

SCABA 6SRGT AGITATOR

PROCHEM MAXFLO T

THE LIGHTNING A315

EKATO INTERMIG
STIRRER GLASS AND BEARINGS APPLICATIONS
It is an equipment that is placed on the
shaft for providing aseptic conditions
inside the vessel

TYPES :
1)THE STUFFING BOX The shaft is sealed with the several layer of
the packing rings of asbestos or cotton yarn
pressed against the shaft

2)THE MECHANICAL SEAL Most commonly used , the seal is composed of

two parts one is stationary in bearing house
and the other is rotating , the two parts are
pressed together

It consist of the two magnets , one driving

4)THE MAGNETIC DRIVE and one driven magnet
 SPARGERS APPLICATION
SPARGER ( THE AERATION SYSTEM) It is a device used to introducing air and
oxygen into the liquid in the fermenter

TYPES : Spargers are the basic need of a fermenter

mostly in case of aerobic fermentations
1) POROUS SPARGER
2) ORIFICE SPARGER
3) NOZZEL SPARGER
4) COMBINED SPARGER AGITATOR
TYPES DIAGRAMS
POROUS SPARGER : made up of sintered glass , ceramics
or metal . These are used in lab scale and are found in non
agitated vessels , the bubble size produce by these sparger
is larger than the pore size .

ORIFICE SPARGER : perforated pipes are arranged below the

impellors in the form of rings or crosses. Air holes are
drilled under side of the pipes making the rings or crosses

NOZZEL SPARGER : it is one of the modern sparger , it is a

single open or partially closed pipe as a sparger to provide
air , the pipe should be positioned centrally below the
impellor . This type of sparger does not get block easily

COMBINED SPARGER AGITATOR : in this the air via a

hollow agitator is introduced to fermenter , the holes are
drilled in the disc between the blades and connected to base
of shaft
 BAFFLES

Baffles are metal strips

usually 1/10th of the vessel
diameter attached to vessel
and its function is to
produce turbulence in flow
and minimize microbial
growth along the fermenter
walls. These are usually
four in number but with
increase in volume of vessel
baffles number can also be
increased
SENSORS AND APPLICATIONS
PROBES
Sensors and probes are devices that report
the presence of specific ions, molecules or
molecular events in vitro or in cells by
communicating a measurable signal

TYPES
1) FOAM PROBES
2) TEMPERATURE CONTROL FOAM CONTROL
3) pH CONTROL MAINTANING TEMPERATURE
4) DISSOLVE OXYGEN SENNSORS MAINTAINING pH
MAINTAINING OXYGEN LEVELS
FOAM CONTROL

It is important to minimize the

foaming

When the foaming became

excessive there is a danger that
the filters in the
Bioreactor becomes wet resulting
in the contamination and can
also interfere with the growth of
microorganisms

To overcome this problem

antifoam agent is use

Foam controlling probes detect

the formation of foam in the
bioreactor and add antifoam
agent automatically
TEMPERATURE CONTROL

Heat is generated by , microbial activity

and continuous agitation
If this heat generated is not ideal for
product formation than the heat should
be either increased or removed from the
system

INCREASE

INTERNAL HEATING COILS

INTERNAL HEATING RODS
HEATING JACKETS
SILICON HEATING MATS

COOLING

COOLING JACKETS
pH CONTROL
pH is a very important factor for the
efficient product formation
Different organisms survives at different
pH hence it is necessity to provide the
system with appropriate pH

The Ph can be adjusted using

appropriate compounds for media and
substrate

Buffers are added to adjust the pH

COMBINED GLASS REFERENCE

ELECTRODE
ELECTRODE MAY BE SILVER/SILVER
CHLORIDE/POTASSIUM CHLORIDE

THE ELCTRODES ARE CONNECTED TO

pH METER VIA LEADS
VALVES AND STREAM TRAPS APPLICATIONS

Valves are the equipments that are used for
controlling the flow of liquid and gases in
variety of ways
TYPES
1) on/off the flow of liquids
2) valves which provide coarse
control of flow rates
3) safety valves which are constructed in
such a way that liquids or gases will flow
only in onZe direction

1) GATE VALVES
2) GLOBE VALVES
3) PISTON VALVES
4) NEEDLE VALVES
5) PLUG VALVES
6) BUTTERFLY VALVES
7) PINCH VALVES
8) DIAPHRAGM VALVES
TYPES DIAGRAM

GATE VALVES : In this valve a sliding disc

is moved in or out of the flow path by
turning the stem of the valve
It can be fully opened or fully closed and
cannot be used for regulation

These valves are not suitable for aseptic

condition as solid mash can pack in the
groove of sliding gate
GLOBE VALVES: A horizontal disc or plug is
raised or lowered from its seating to control
the rate of flow
This valve can be adjusted thus can regulate
the flow of liquid and gases

It is not suitable for aseptic operations for

same reason as in globe valve
PISTON VALVES : It is similar to that of
globe valve except that the flow is controlled
by piston passing between two packing rings
This valve is known to handle at aseptic
conditions but it has to be sterlize partly
open so that the steam can reach as far as
possible

There can be blockage by the mycelial

culture

NEEDLE VALVES : It is similar to that of

the globe valve except that the disc is
replaced by the tapered plug or needle fitted
in the valve

The flow can be finely regulateed

PLUG VALVES : Plug valves are valves with
cylindrical or conically tapered "plugs" which
can be rotated inside the valve body to
control flow through the valve. The plugs in
plug valves have one or more hollow
passageways going sideways through the
plug, so that fluid can flow through the plug
when the valve is open.

BUTTERFLY VALVE : consist of a disc which

rotates about a shaft
The disc stops to stop the flow
this type of the valve are used in the large
diameter pipes

It is not suitable for the aseptic operation

BALL VALVES : It has been developed from
the plug valve , the valve contain a stainless
steal ball which contain an orifice . The
orifice can be of the same diameter as of
pipeline to get a proper flow path

The ball is fitted between the two wiping

surfaces which wipe the surface and
prevents deposition of the matter

Aseptic conditions Can be maintained even

in mycelial cultures
 MOST SUITABLE VALVES
Among these valves globe and butterfly valve
are most commonly used for on/off
applications
Gate valves for crude flow control
Needle flow for accurate control flow
Ball or diaphragm valve for all sterile users
and are nowdays widely used in fermenters
OTHER IMPORTANT VALVES APLLICATIONS

SAFETY VALVES they should be incorporated in every steam

and gas line to make sure that the pressure
do not exceeds the set point

CHECK VALVES The purpose of the check valves is to prevent

the reversible flow of liquid or gas in pipe
due to the breakdown of the some part in the
fermenter

PRESSURE CONTROL VALVES PRESSURE CONTROL VALVES are used to

control the pressure inside the vessel
STERLIZATION CONDITIONS
STERLIZATION OF FERMENTER
STRELIZATION O AIR SUPPLY
STERLIZATION OF EXHAUST AIR
INOCULUM AND MEDIA
FEED PORT / SAMPLING PORT
METHODS
Steam sterlization under pressure
1)Filtration of air is the most commonly used
sterilization in fermentation industries. Depth
filters: When the air is passed through a
glass wool containing depth filters the
particles are trapped and removed
2)heat, irradiation
Achieved by filters on the outlet
They can clog thus should be monitored on
regular bases
Sterilisation of fermentation media is done
by , Boiling, or passing steam through media.
The synthetic media can be sterilized in short
time where as crude media requires more time
for sterilization
Addition of media and removal of sample is
done by silicon pipes autoclaved separately
TYPES OF FERMENTER VESSELS
STIRRED TANK FERMENTER
PACKED TOWER
ROTATING DISC FERMENTER
AIR LIFT FERMENTERS
PACKED GLASS BEAD REACTORS
BUBBLE COLOUMN FEREMTERS
 REFERENCES
Principles of fermentation technology P.F
STANBURY A. WHITAKER AND S.J. HALL

https://www.researchgate.net/
publication/358265321_FERMENTATION_TYP
ES_OF_FERMENTERS_DESIGN_USES_OF_FER
MENTERS_AND_OPTIMZATION_OF_FERMENT
ATION_PROCESS
THANKYOU