Fermentation and Biochemical Engineering Handbook, Third Edition

455 Pages·2014·22.72 MB·English

by  Celeste M. Todaro

Fermentation and Biochemical
Engineering Handbook
Principles, Process Design, and Equipment
ThirdEdition
Dedication
For Mother
For Walter, Christian, Brandon
For David, Kathy, David
Fermentation and Biochemical
Engineering Handbook
Principles, Process Design, and Equipment
Third Edition
Edited by
Henry C. Vogel
Chapel Hill, WC
Celeste M. Todaro
CelesTech Inc., Haddonfield, New Jersey
AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON(cid:129)NEWYORK(cid:129)OXFORD(cid:129)PARIS
SANDIEGO(cid:129)SANFRANCISCO(cid:129)SINGAPORE(cid:129)SYDNEY(cid:129)TOKYO
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Contents
PrefacetotheThirdEdition xiii 3. Bioreactors for Plant Cell Tissue and
PrefacetotheSecondEdition xv Organ Cultures 25
PrefacetotheFirstEdition xvii
InMemoryofHenryC.Vogel xviii ShinsakuTakayama
ListofContributors xix
1.0 BackgroundoftheTechnique—Historical
Overview 25
2.0 MediaFormulations 25
Part I 3.0 GeneralApplications 26
4.0 Bioreactors—HardwareConfiguration 27
Fermentation 5.0 BioreactorSize 30
6.0 CulturePeriod 30
7.0 AerationandAgitation 31
1. Fermentation Pilot Plant 3
8.0 MicrobialContamination 31
YujiroHarada,KuniakiSakata,SeijiSato 9.0 Characteristics 31
andShinsakuTakayama 10.0 Manipulation 32
11.0 Scale-upProblems 33
Prologue 3 12.0 BioprocessMeasurementandControl 34
1.0MicrobialFermentation 3 References(Section3) 35
1.1 FermentationPilotPlant 3 FurtherReading 36
1.2 BioreactorsandCultureTechniques
forMicrobialProcesses 4 4. Nutritional Requirements in
1.3 ApplicationofComputerControland Fermentation Processes 37
SensingTechnologiesfor
FermentationProcess 5 WillemH.Kampen
1.4 Scale-Up 13
1.0 Introduction 37
1.5 BioreactorsforRecombinantDNA 2.0 NutritionalRequirementsoftheCell 38
Technology 13 3.0 TheCarbonSource 40
FurtherReading 14 4.0 TheNitrogenandSulfurSource 42
5.0 TheSourceofTraceandEssentialElements 44
6.0 TheVitaminSourceandOther
2. Mammalian Cell Culture System 17
GrowthFactors 48
7.0 PhysicalandIonicRequirements 51
SeijoSato
8.0 MediaDevelopment 52
1.0 Introduction 17 9.0 EffectofNutrientConcentrationon
2.0 CultureMedia 17 GrowthRate 53
3.0 MicrocarrierCultureandGeneralControl References 57
Parameters 18 FurtherReading 57
4.0 PerfusionCultureSystemsasaNewHigh
DensityCultureTechnology 18 5. Fermentation for Biofuels and
5.0 SedimentationColumnPerfusion
Bio-Based Chemicals 59
Systems 20
6.0 HighDensityCultureUsingaPerfusion SteveLicht
CultureSystemwithSedimentation
Column 21 1.0 Introduction,History,andTheory 59
Acknowledgment 23 1.1 TheBiofuelandBio-BasedChemical
ReferencesandBibliography(Section2) 23 IndustriesOriginatedwithNatural
FurtherReading 24 FermentationProducts 59
v
vi Contents
Part II
1.2 Theory:PrinciplesofChemistryand
BiologyGuidetheSelectionof
Equipment Design
FermentationProducts,Substrates,
andOrganisms 60
6. Fermentation Design 85
1.3 HistoricalFoundationofBiofuel-and
Bio-BasedChemicalFermentation AllanC.Soderberg
Industries 62
1.0 Introduction 85
2.0 FermentationOrganismDevelopment
2.0 FermentationDepartment,Equipmentand
foraBiofuel-orBio-BasedChemical
SpaceRequirements 85
Product 66
2.1 TheMicrobiologicalLaboratories 85
2.1 NativeStrainScreening,Selection,
2.2 AnalyticalSupportLaboratories 86
andGeneticModification 66
2.3 Production:RawMaterialStorage 87
2.2 AdaptiontotheFermentation
2.4 MediaPreparationorBatchingArea 87
BackgroundandLowestCostNutrient
2.5 TheSeedFermenterLayout 87
Mix,toOvercomeInhibitionand
2.6 TheMainFermenterLayout 88
MinimizeOperatingCosts 67
3.0 Biofuel-orBio-BasedChemical 2.7 NutrientFeedTanks 88
FermentationProcessDevelopment 2.8 SterileFilters 88
andDesign 68 2.9 AirCompressors 89
4.0 PracticalApplications 69 2.10 Valves(toMaintainSterility) 89
4.1 Selection 69 2.11 Pumps 90
4.2 CriticalFactors 69 2.12 CoolingEquipment 90
4.3 Troubleshooting 69 2.13 EnvironmentalControl 90
5.0 PlantOperations 70 3.0 GeneralDesignData 90
6.0 References 70 4.0 ContinuousSterilizers 91
7.0 ExamplesofBiofuel-andBio-Based 4.1 AJustificationforContinuous
ChemicalIndustrialProduction Sterilization 91
Processes 70
4.2 SupportEquipmentforaSterilizer 91
7.1 CurrentBiofuelsTechnologies:Overview
4.3 TheSterilizingSection 94
oftheProductionProcessesforFuel
4.4 TheCoolingSection 94
GradeEthanolfromCorn,Wheat,or 5.0 FermenterCooling 97
BarleyintheUnitedStates,Canada, 6.0 TheDesignofLargeFermenters(Basedon
andEurope 70 Aeration) 98
7.2 TheEmergingNext-Generation 6.1 AgitatorEffectiveness 98
BiofuelIndustry:Examplesof 6.2 FermenterHeight 99
20CompaniesDevelopingNew 6.3 MixingHorsepowerbyAeration 99
Bio-BasedProductsand/orWorking 6.4 AirSpargerDesign 102
withNewSubstrates 73 6.5 ComparisonofShearofAirBubblesby
7.3 OPXBioOrganismAdvanced AgitatorsandJets 102
RapidDevelopmentMethod 6.6 TheEffectofShearonMicroorganisms 103
Overview 76 6.7 OtherExamplesofJetAir/LiquidMixing 103
7.4 ICMCellulosicEthanolExample: 6.8 MechanicalVersusNon-mechanical
ImprovingCornEthanolPlantYield Agitation 103
withCellulosicBolt-OnTechnology 76 7.0 TroubleshootinginaFermentationPlant 104
7.5 INEOSBIO:AnExampleofNon- 8.0 GeneralComments 107
ConventionalFermentationProcess References 107
withSynthesisGases(CO,H ,
2
CO2)GeneratedfromMunicipal 7. Agitation 109
SolidWasteasSubstratefor
BacterialFermentationtoEthanol 78 JamesY.Oldshue
7.6 ARepresentativeListofCellulosicand
1.0 TheoryandConcepts 109
Non-TraditionalBiofuelProduction 2.0 PumpingCapacityandFluid
Processes,UnderDevelopmentor ShearRates 109
EnteringCommercialDemonstrations, 3.0 MixersandImpellers 109
2000(cid:1)2013 80 3.1 FluidfoilImpellers 110
Contents vii
4.0 Baffles 114 12.0 BHSAutopress 147
5.0 FluidShearRates 115 12.1 Applications 147
5.1 Particles 117 12.2 Operation 147
5.2 ImpellerPowerConsumption 118 13.0 Manufacturers 148
5.3 MassTransferCharacteristics 13.1 RotaryDrumVacuumFilters 148
ofFluidfoilImpellers 123 13.2 Nutsches 148
6.0 Full-ScalePlantDesign 123 13.3 Autopress 148
6.1 SomeGeneralRelationshipsinLarge References 148
ScaleMixersComparedtoSmall FurtherReading 148
ScaleMixers 123
6.2 ScaleupBasedonDatafrom
ExistingProductionPlant 124 9. Cross-Flow Filtration 149
6.3 DataBasedonPilotPlantWork 125
6.4 SulfiteOxidationData 126 RameshR.Bhave
6.5 OxygenUptakeRateintheBroth 127
1.0 Introduction 149
6.6 SomeGeneralConcepts 127 2.0 Cross-flowvs.DeadEndFiltration 149
6.7 ReverseRotationDualPowerImpellers 127 3.0 ComparisonofCross-FlowwithOther
7.0 FullScaleProcessExample 128 CompetingTechnologies 152
8.0 TheRoleofCellConcentrationonMass 4.0 GeneralCharacteristicsofCross-Flow
TransferRate 128 Filters 152
9.0 SomeOtherMassTransfer 4.1 PolymericMicrofiltersand
Considerations 130
Ultrafilters 153
10.0 DesignProblemsinBiochemical
4.2 InorganicMicrof¨ıltersandUltrafilters 154
Engineering 131
5.0 OperatingConfigurations 156
11.0 Solution—FermentationProblems 131
5.1 BatchSystem 156
ListofAbbreviations 132
5.2 FeedandBleed 157
FurtherReading 133
5.3 Singlevs.MultistageContinuous
System 159
6.0 ProcessDesignAspects 160
Part III
6.1 MinimizationofFluxDeclinewith
Recovery BackpulseorBackwash 160
6.2 UniformTransMembranePressure
8. Filtration 137 Filtration 162
6.3 EffectofOperatingParametersonFilter
CelesteM.Todaro
Performance 164
1.0 Introduction 137 6.4 MembraneCleaning 168
1.1 DepthFiltration 137 6.5 PilotScaleDataandScaleup 170
2.0 CakeFiltration 137 6.6 Troubleshooting 170
3.0 Theory 137 6.7 CapitalandOperatingCost 170
3.1 FlowTheory 137 6.8 SafetyandEnvironmental
3.2 CakeCompressibility 137 Considerations 172
4.0 ParticleSizeDistribution 138 7.0 ApplicationsOverview 172
5.0 OptimalCakeThickness 138 7.1 ClarificationofFermentationBroths 172
6.0 FilterAid 139 7.2 PurificationandConcentrationof
7.0 FilterMedia 139 Enzymes 172
8.0 EquipmentSelection 140
7.3 MicrofiltrationforRemovalof
8.1 PilotTesting 140
MicroorganismsorCellDebris 173
9.0 Continuousvs.BatchFiltration 141
7.4 ProductionofBacteria-freeWater 173
10.0 RotaryVacuumDrumFilter 141
7.5 ProductionofPyrogen-freeWater 175
10.1 OperationandApplications 141
8.0 GlossaryofTerms 175
10.2 Optimization 144 Acknowledgment 177
11.0 Nutsches 144
Appendix:ListofMembraneManufacturers
11.1 Applications 144 (MicrofiltrationandUltrafiltration) 177
11.2 Operation 144 References 179
11.3 Maintenance 146 FurtherReading 180
viii Contents
10. Distillation for Recovery of Biofuels 11. Solvent Extraction 225
and Bio-Based Chemicals 181
DavidB.Todd
SteveLicht
1.0 ExtractionConcepts 225
1.0 IntroductionandTheory 181 1.1 TheoreticalStage 226
1.1 IntroductionwithHistorical 2.0 DistributionData 226
3.0 SolventSelection 227
Background 181
4.0 CalculationProcedures 227
1.2 HowaDistillationSystemWorks 181
4.1 SimplifiedSolution 229
1.3 TheoryofMulti-Component
4.2 SampleStageCalculation 229
Vapor-LiquidEquilibrium(VLE)
5.0 DropMechanics 231
RelationshipsthatDetermine
6.0 TypesofExtractionEquipment 232
Distillation
6.1 Non-AgitatedGravityFlow
ProcessFeasibilityandCapability 187
Extractors 232
2.0 DevelopmentofaDistillation
6.2 StirredGravityFlowExtractors 233
Application 193
6.3 PulsedGravityFlowExtractors 234
2.1 UsingVLEInformationforConceptual
6.4 CentrifugalExtractors 235
DistillationProcessSynthesis 193
6.5 EquipmentSizeCalculation 235
2.2 UsingaComputerProcessSimulatorto
7.0 SelectionofEquipment 237
ModelaCandidateDistillation
8.0 ProcedureSummary 238
Process 194
9.0 AdditionalInformation 238
2.3 SelectionofColumnInternal References 238
ContactingEquipment 195
2.4 RatetheSelectedPhysical
12. Evaporation 239
DistillationColumnfor
AlternativeOperations 195 HowardL.Freese
3.0 DesignofaDistillationSystemforaNew
1.0 Introduction 239
Application 196
2.0 EvaporatorsandEvaporationSystems 239
3.1 LaboratoryTestingforDesign
3.0 LiquidCharacteristics 241
ofaCommercialScaleDistillation
4.0 HeatTransferinEvaporators 242
System 196
5.0 EvaporatorTypes 245
3.2 HowtoDesignaCompletelyNew
5.1 JacketedVessels 246
DistillationSystem 198
5.2 HorizontalTubeEvaporators 247
4.0 ControlandAutomationofDistillation
5.3 Short-TubeVerticalEvaporators 247
Systems 204
5.4 PropellerCalandrias 247
4.1 PracticalandTheoreticalAspectsof
5.5 Long-TubeVerticalEvaporators 247
ControllingaCommercial
5.6 FallingFilmEvaporators 248
DistillationSystem 204
5.7 ForcedCirculationEvaporators 249
4.2 PLCandDCSSystemSoftware
5.8 PlateEvaporators 250
DevelopmentforControlofa
5.9 MechanicallyAgitatedThin-Film
DistillationSystem 212
Evaporators 251
4.3 ImplementingFullyAutomated
5.10 FlashPotsandFlashEvaporators 252
OperationUsingISAS88.01Model
5.11 MultipleEffectEvaporators 253
forBatchControl 213
6.0 EnergyConsiderationsforEvaporation
5.0 DistillationPlantOperations 220
SystemDesign 254
5.1 StartupPreparationsandNormal
7.0 ProcessControlSystemsforEvaporators 258
Operation 220
8.0 EvaporatorPerformance 260
5.2 PerformanceTesting 221 9.0 HeatSensitiveProducts 261
5.3 Troubleshooting 221 10.0 InstallationofEvaporators 262
5.4 SafetyConcernsandEmergency 11.0 TroubleshootingEvaporationSystems 263
Handling 222 ReferencesandSelectedReading
5.5 DistillationSystemShutdown 223 Material 264
References 223 FurtherReading 265
Contents ix
13. Centrifugation 267 3.2 CostEstimation 291
3.3 InstallationConcerns 292
CelesteM.Todaro
3.4 SafetyConsiderations 293
1.0 Introduction 267 4.0 EquipmentManufacturers 294
2.0 Theory 267 5.0 DirectoryofManufacturers 294
3.0 EquipmentSelection 268 FurtherReading(forSectionI:
IndirectDrying) 294
3.1 PilotTesting 268
SectionII DirectDrying 295
3.2 DataCollection 268
1.0 Introduction 295
3.3 MaterialsofConstruction 270
2.0 Definitions 295
4.0 ComponentsoftheCentrifuge 270
3.0 PsychrometricCharts 296
5.0 SedimentationCentrifuges 271
4.0 DryingTheory 296
6.0 Tubular-BowlCentrifuges 271
5.0 FundamentalAspectsofDryer
6.1 Operation 271
Selection 297
7.0 ContinuousDecanterCentrifuges
5.1 BatchDirectDryers 297
(WithConveyor) 271
5.2 BatchFluidBedDryers 297
7.1 Maintenance 271
5.3 BatchRotaryDryers 298
7.2 TypicalProblemforContinuous
5.4 RibbonDryers 298
DecanterCentrifugewithConveyor 272
5.5 PaddleDryers 298
8.0 DiskCentrifuges 272
5.6 AgitatedPanDryers 298
8.1 Operation 273
5.7 ContinuousDryers 299
8.2 Maintenance 273
5.8 SprayDryers 299
9.0 FilteringCentrifugesvs.Sedimentation
Centrifuges 273 5.9 FlashDryers 299
10.0 FilteringCentrifuges 273 5.10 RingDryers 299
10.1 CakeWashing 273 5.11 MechanicallyAgitatedFlash
11.0 VerticalBasketCentrifuges 274 Dryers 299
11.1 Applications 274 5.12 RotaryTrayorPlateDryers 300
11.2 SolidsDischarge 275 5.13 FluidBedDryers 300
11.3 OperationalSpeeds 275 6.0 DataRequirements 300
11.4 Maintenance 275 7.0 SizingDryers 301
12.0 HorizontalPeelerCentrifuge 275 7.1 SprayDryers 301
12.1 Applications 275 7.2 FlashDryers 302
12.2 Operation 275 7.3 TrayDryers 302
13.0 InvertingFilterCentrifuge 276 7.4 FluidBedDryers 303
13.1 Operation 276 7.5 BeltorBandDryers 303
13.2 Maintenance 277 8.0 SafetyIssues 303
14.0 Maintenance:Centrifuge 278 8.1 SpecificFeatures 304
14.1 Bearings 278 9.0 Decisions 304
15.0 Safety 279 10.0 TroubleShootingGuide 304
16.0 PressureandCentrifugation 279 11.0 RecommendedVendorsList 305
17.0 Manufacturers 280 FurtherReading(forSectionII:
17.1 FilteringCentrifuges 280 DirectDrying) 305
17.2 SedimentationCentrifuges 280
Part IV
17.3 OxygenAnalyzers 280
References 280 Purification
FurtherReading 280
15. Crystallization 309
14. Drying 283
StephenM.Glasgow
BarryFox,GiovanniBelliniandLauraPellegrini
1.0 Introduction 309
SectionI IndirectDrying 283 2.0 Theory 309
1.0 Introduction 283 2.1 FieldofSupersaturation 309
2.0 Theory 283 2.2 FormationofaSupersaturatedSolution 310
3.0 EquipmentSelection 285 2.3 AppearanceofCrystallineNuclei 310
3.1 TestingandScale-Up 289 2.4 GrowthofNucleitoSize 310