I. Overview
(scale down)：Large-scale fermentation production conditions were used as small- and medium-scale experimental conditions.
(scale up)：Laboratory and pilot plant results are applied to the large-scale fermentation industry.
II. Key factors for zooming in or out
Analysis of environmental conditions for small and large equipment (as consistent as possible)
· Chemical factors: substrate, precursor concentration, etc., which can be kept constant by human control;
· Physical factors: temperature, bacterial concentration, viscosity, pressure, power consumption, shear, etc.
III. The process of amplification
In the first phase, laboratory scale, screening of strains and research on culture media was carried out
Fig. 1 KNIKBIO laboratory bioreactor
In the second phase, the pilot plant was scaled up to determine the optimal operating conditions for strain cultivation.
Figure 2 KNIK BIO pilot plant
Phase III, factory mass production.
KNIK BIO large-scale production engineering project
IV. Principles and guidelines for the scale-up of bioreactors
Similar conditions that should be achieved for ideal reactor scale-up:
1、Geometric similarity
2、Hydrodynamic similarity
3、Thermodynamic similarity
4、Mass (concentration) similarity
5、Biochemical similarity
Principles of Bioreactor Amplification – Similarity Principle
That is, if the biochemical reaction processes, fluid flow and momentum transfer, and heat and mass transfer processes of an experimental reaction system and an amplified reaction system can be described by the same differential equations and have the same characteristics, the two systems have the same mode of behaviour.
V. Scale-up methods for bioreactors
– Experience Amplification Method
– Reduction-amplification method
– Factorial analysis
– Mathematical modelling
VI. Design of aerated fermenters – empirical amplification method
1. Geometrically similar enlargement
Enlargement in proportion to the geometric dimensions of each component of the reactor. Amplification is actually the multiplier of the reactor.
Second, constant equal volume stirring power amplification
This method is suitable for biological fermentation with dissolved oxygen rate control fermentation reaction, non-Newtonian fluid with high viscosity or high cell density culture.
Third, constant volume dissolved oxygen coefficient amplification
This method is suitable for Newtonian fluids, high oxygen consumption fermentation (bacterial fermentation, yeast fermentation) fermentation process of the reactor amplification.
Four, constant stirring blade tip line end speed amplification
It is suitable for the amplification of fermentation processes in which biological cells are significantly affected by stirring shear, such as the fermentation of filamentous bacteria.
The stirring blade tip speed (πDn) is the key to determine the intensity of stirring shear.
5. Constant mixing time amplification
Mixing time is the time it takes to add materials to the reactor until they are well mixed. In a small reactor, it is easier to mix homogeneously, while in a large reactor, it is more difficult.
Six, air flow amplification
(1) to the same principle of amplification of air flow per unit volume of culture fluid
(2) to the same principle of air linear flow rate amplification
(3) to KLa value of the same principle of amplification
Guidelines for amplification in the European fermentation industry
| Proportion of industrialapplications (%) | Empirical amplification benchmarks used |
| 30 | Equal power consumption per unit volume of culture solution |
| 30 | Kla constant |
| 20 | Constant speed at the mixing paddle end |
KNIK BIO has rich experience in the manufacture of various types of reactors and pressure vessels. With a team of experts in the fields of biological reaction, fermentation process, machinery manufacturing and automation control, our scientific research and technology are always in the leading position in China and the international first-class level, providing you with comfortable, assured and reassuring product experience.