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Scaleup and Optimization of Oxygen Transfer in Fermentors

The basic function of scaleup is to determine the operating conditions in equipment of different size and mass transfer characteristics so as to achieve the same process yield. A typical problem is the determination of operating conditions in existing large-scale equipment that will provide similar oxygen transfer as observed in laboratoryscale fermentors. In most fermentations of industrial importance, the critical substrate is oxygen due to its low solubility in water. For good process productivity, it is important to supply sufficient oxygen to satisfy the needs of the microorganism. However, supplying excessive oxygen is wasteful of power and may even lead to poor performance due to oxygen toxicity in some unusual cases. One way of ensuring adequate oxygen availability is to determine operating conditions that keep the dissolved oxygen concentrations above predetermined critical levels in all parts of the fermentor. In order to minimize power consumption, these operating conditions should be such that the dissolved oxygen levels are not kept higher than necessary. The work here will be restricted to geometrically similar stirred-tank fermentors. These units are common in the industry because of their versatility and somewhat standardized design. The main operating conditions that must be optimized are the agitator speed and the aeration rate. Suitable methods for the design of equipment for both Newtonian as well as nowNewtonian fermentation broths will be discussed. On-line techniques will be developed for the continuous optimization of oxygen transfer efficiency.