Fermentation Pilot Plant 11 Ma intrant c。■putr EWMAC 300 Line Computer Ma in Menory: ROM 16KB +RAM 14B Hard Di sk: 10MB, FDD: 13 RAN 512 K8 TOSNET SM1 4 BsC auIti-point system MODEM MODEM 14MOOEW 1|UCIA-2 #2 UCIA-2 #3 UCIA-2 f4UClA-2 UOPC #1 OPC #2 OPC #3 UoPS t1 FCu #1 UFCU #1 UFCU #1 uFCH盖1 2 UOPC(UOPS): Operator conso FCU (UFCH): FieId control unit. CIA-2: RS232c comunication Figure 4. Local area network for pilot fermentation plant
Fermentation Pilot Plant 11 Mainframe Computer Printer YEWMAC 300 Line Computer Main Memory: ROY l6KB tRAY 1YB Hard Disk: IOYB. FDD: 1YB 1 Linb controller 3610C Main Ybmory: ROM 16 KB CRT 111 BSC multi-point ryrtom UOPC (UOPS) :Operator console. UFCU (UFCH) :Fib Id contro I un i 1. UCIA-2: RS232C conmunication i ntbrf IC(. Figure 4. Local area network for pilot fermentation plant
12 Fermentation and Biochemical Engineering Handbook Analogue output Minicomputer or Pc Digital outpu Pressure Amplifier Mass spectrometer Exit gas Medium vessel Deformer Mu|tip|X自r reservoIr Load cel Load cel l converter Fer雷ntor ORP TIC Temperature Cooling water Autosampler Bis自nsor HPLc etc Air fI。 w rate RPM, torque HH 3 PHIC Agitation Torque or Figure 5. Highly instrumented pilot fermentor for fed-batch operations
12 Fermentation and Biochemical Engineering Handbook coo I wate -. Ag i Tor wat Autosampler Biosensors Air flow rate - 0 - APM. torque PHlC DIC Figure 5. Highly instrumented pilot fermentor for fed-batch operations
Fermentation Pilot Plant 13 Sensing in the fermentation area tends to lack the standard of reliability common to the chemical industry. Steam sterilization to achieve aseptic needs in fermentation is crucial for most sensors such as specific enzyme sensors. The various sensors that can be used in fermentation are summarized in Table 6. As in the chemical industry, almost all the physical measurements can be monitored on-line using sensors, although an accurate measurement device, such as a flow meter, is not yet available. the chemical sensors listed in Table 6 reflect the measurement ofextracellular environmental conditions The concentration of various compounds in the media are currently deter mined off-line following a manual sampling operation except for dissolved gas and exhaust gas concentration. Exhaust gas analysis can provide significant information about the respiratory activity which is closely related to cellular metabolism and cell growth. This analysis is what is called gateway sensor and is shown schematically in Fig. 6 Table 6. Sensors for Fermentation Processes Physical Chemical Temperature ORP Shaft speed Heat transfer rate Heat production rate Gaseous CO, concentration Dissolved O2 concentration Gas flow rate Dissolved CO2 concentration Liquid Flow Rate* Carbon source concentration Broth volume or weight Nitrogen source concentration* Turbidity* Metabolicproduct concentration* Rheology or viscosity* Minor metal concentration* Nutrient concentration Biochem Viable cell concentration* NAD/NADH level ATP/ADP/AMP/level* Enzyme Activity Broth composition *Reliable sensors are not available
Fermentation Pilot Plant 13 Sensing in the fermentation area tends to lack the standard of reliability common to the chemical industry. Steam sterilization to achieve aseptic needs in fermentation is crucial for most sensors such as specific enzyme sensors. The various sensors that can be used in fermentation are summarized in Table 6. As in the chemical industry, almost all the physical measurements can be monitored on-line using sensors, although an accurate measurement device, such as a flow meter, is not yet available. The chemical sensors listed in Table 6 reflect the measurement of extracellular environmental conditions. The concentration of various compounds in the media are currently determined off-line following a manual sampling operation except for dissolved gas and exhaust gas concentration. Exhaust gas analysis can provide significant information about the respiratory activity which is closely related to cellular metabolism and cell growth, This analysis is what is called gateway sensor and is shown schematically in Fig. 6. Table 6. Sensors for Fermentation Processes Physical Chemical Temperature Pressure Shaft speed Heat transfer rate Heat production rate Foam Gas flow rate Liquid Flow Rate* Broth volume or weight Turbidity * Rheology or viscosity* Biochemical Viable cell concentration* NAD/NADH level* ATP/ADP/AMP/level* Enzyme Activity' Broth composition* PH OW Ionic strength Gaseous 0, concentration Gaseous CO, concentration Dissolved 0, concentration Dissolved CO, concentration Carbon source concentration Nitrogen source concentration* Metabolic product concentration* Minor metal concentration* Nutrient concentration* *Reliable sensors are not available
14 Fermentation and Biochemical Engineering Handbook r flo rat copout substrate Agitation altering Product darK/(002k)sar Metabolie st Figure 6. Estimation of metabolic parameters using gateway sensor. The data analysis scheme of Fig. 6 includes the steady-state oxygen balance method and the carbon balancing method In addition, the system can provide the oxygen supply conditions that relate to volumetric oxygen transfer coefficient(k a), oxidation-reduction potential (ORP)and degree of oxygen saturation Qo2X/(Qo2X)max. For the data analysis scheme of Fig. 6, the most significant advance in the fermentation field has been the develop ment of steam sterilization, dissolved oxygen electrodes and the application of mass spectrometry to the exhaust gas analysis, Dissolved oxygen probes can be classified as either potentiometric (galvanic)or amperometric(po larographic). These electrodes are covered with a gas-permeable membrane an electrolyte is included between the membrane and the cathode. It should be noted that these probes can measure the oxygen tension but not the concentration. The signal from both models of electrodes often drifts with time for long continuous measurements. Calibration then becomes difficult because of possible contamination. Most commercial probes have a vent to balance the pressure between the inside and outside of the probe. Often, the broth and electrolyte mix through the vent causing signal drift and rapid reduction in probe life. Therefore, fiber-optic chemical sensors such as pH, dissolved oxygen and carbon dioxide electrodes which need pressure com pensation interference by medium components, drift and so on. This type of sensor is based on the interaction of light with a selective indicator at the
I4 Fermentation and Biochemical Engineering Handbook I I Figure 6. Estimation of metabolic parameters using gateway sensor. The data analysis scheme of Fig. 6 includes the steady-state oxygen balance method and the carbon balancing method. In addition, the system can provide the oxygen supply conditions that relate to volumetric oxygen transfer coefficient &a), oxidation-reduction potential (OW) and degree of oxygen saturation Qo2X/(Qo2X),,. For the data analysis scheme of Fig. 6, the most significant advance in the fermentation field has been the development of steam sterilization, dissolved oxygen electrodes and the application ofmass spectrometry to the exhaust gas analysis. Dissolved oxygen probes can be classified as either potentiometric (galvanic) or amperometric (polarographic). These electrodes are covered with agas-permeable membrane; an electrolyte is included between the membrane and the cathode. It should be noted that these probes can measure the oxygen tension but not the concentration. The signal from both models of electrodes often drifts with time for long continuous measurements. Calibration then becomes difficult because of possible contamination. Most commercial probes have a vent to balance the pressure between the inside and outside ofthe probe. Often, the broth and electrolyte mix through the vent causing signal drift and rapid reduction in probe life. Therefore, fiber-optic chemical sensors such as pH, dissolved oxygen and carbon dioxide electrodes which need pressure compensation interference by medium components, drift and so on. This type of sensor is based on the interaction of light with a selective indicator at the