CHE 514A: BIOCHEMICAL ENGINEERING

CONTINUOUS STERILIZATION

Advantages of continuous sterilization are:

1. It simplifies production planning, thus allowing maximum plant utilization and minimum delays.
2. It provides reproducible conditions.
3. It can be operated at a high temperature (140°C instead of 121°C in batch sterilization); therefore, the
sterilization time can be shortened (holding time of 1 to 2 minutes).
4. It can reduce damage to other medium ingredients.
5. The amount of steam is reduced to around 20-25% to that used in batch since heating and cooling occur
simultaneously.
6. It requires less steam by recovering heat from the sterilized medium. As a result, it also requires less cooling
water.
7. It is easier to automate the process; thus, it is less labor intensive.

A continuous sterilizer consists of three main sections: heating, holding, and cooling just like in batch sterilization. The
following figure shows typical continuous sterilization units.

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As you can imagine for continuous sterilization, there is a continuous input of new medium and continuous exit of
sterilized medium. For the first figure, the type of heating method used is steam injection and the second figure makes
use of a plate exchanger. The holding stage is still the most important since maximum temperature is maintained here.
Because the sterilization process is continuous, the holding stage occurs in holding tubes.

Heating Section

Two types:
a. Direct steam injection
b. Indirect heating in shell-and-tube or plate-and-frame heat exchanger
The temperature change with respect to residence time (𝜏̅) as the medium passes through an isothermal heat
source can be approximated as (Deindoerfer and Humphrey, 1959b)
−𝑈𝐴𝜏̅ℎ𝑒𝑎𝑡
𝑇𝐶2 = 𝑇𝐻 − (𝑇𝐻 − 𝑇𝐶1 )𝑒𝑥𝑝 ( )
𝑐𝑊
For heating using a countercurrent heat source of equal flow rate and heat capacity,
∆𝑇𝑈𝐴𝜏̅ℎ𝑒𝑎𝑡
𝑇𝐶2 = 𝑇𝐶1 +
𝑐𝑊
Where:

Holding Section

The holding section is maintained in adiabatic conditions. If the heat loss in the section is negligible, the
temperature can be assumed constant. The average residence time in the holding section is
𝐿
𝜏̅ℎ𝑜𝑙𝑑 =
𝑢̅
The Del factor during holding can be estimated as
𝑛0 −𝐸𝑎
∇ℎ𝑜𝑙𝑑 = ln = 𝑘𝑑 𝜏̅ℎ𝑜𝑙𝑑 = 𝑘𝑑0 𝑒𝑥𝑝 ( ) 𝜏̅
𝑛 𝑅𝑇 ℎ𝑜𝑙𝑑

An important variable affecting performance of continuous sterilizers is the nature of fluid flow in the system.
Ideally, all fluid entering the equipment at a particular instant should spend the same time in the sterilizer and

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exit the system at the same time; unless this occurs we cannot fully control the time spent in the steriliser by all
fluid elements. No mixing should occur in the tubes; if fluid nearer the entrance of the pipes mixes with fluid
ahead of it, there is a risk that contaminants will be transferred to the outlet of the sterilizer. The type of flow in
pipe where there is neither mixing nor variation in fluid velocity is plug flow.

In reality, fluid elements in pipes have a range of different velocities. As you can see from the velocity profiles in
the previous page, flow tends to be faster through the center of the tube than near the walls, which is true for
laminar flow. Plug flow is approached in pipes at turbulent flows. High Reynolds numbers minimises fluid mixing
and velocity variation.

If the medium in a holding section behaves as ideal plug flow, the residence time of the medium in the section
will be exactly the same for all the medium. However in reality, due to some factors, these causes deviation
from the ideal plug flow. The deviation is characterized by the degree of axial dispersion in the system.

Axial Dispersion – degree at which mixing occurs along the length or axis of the pipe.
- Degree of back mixing during flow.
- This coefficient can give be used to check how severe the mixing is that occurs inside the
tubes. If D = 0, this means that the flow is close to ideal plug flow while if D = large, then the
medium is well mixed.

The deviation from ideal plug flow due to the axial mixing can be described by the dispersion model.

By using cell balance around the bulk flow and axial dispersion condition, then simplifying the total cell balance
by using dimensionless numbers. (The detailed derivation of the equation is present in your book.) The final equation used
to estimate the length of holding tubes is
4𝜁exp⁡(0.5𝑃𝑒)
𝐶′𝑛 =
(1 + 𝜁)2 exp(0.5𝜁𝑃𝑒) − (1 − 𝜁)2 exp⁡(−0.5𝜁𝑃𝑒)

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Where:
𝐶𝑛
𝐶′𝑛 =
𝐶𝑛0
4𝑘𝑑 𝐿
𝜁 = √1 +
𝑢⁡𝑃𝑒
𝑢𝐿
𝑃𝑒 = ; Peclet number = a dimensionless number representing the importance of axial
𝐷
dispersion and bulk flow in transfer of material

Where: Cn = final bacteria conc’n

Cn0 = initial bacteria conc’n
kd = specific death constant
L = length of holding tubes
u = velocity of medium
D = axial dispersion coefficient

The axial dispersion coefficient can be estimated by using the graph below. By using the Re on
the x-axis, project the computed Re to the curve on the graph then project on the y-axis. A D/udt value
will be read and you can just cross multiply u (velocity) and dt (tube diameter) to get D (axial dispersion
coefficient).

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Cooling Section

The temperature versus residence time relationship for cooling using an isothermal heat sink is
𝑈𝐴𝜏̅𝑐𝑜𝑜𝑙
𝑇𝐻2 = 𝑇𝐶 − (𝑇𝐶 − 𝑇𝐻1 )𝑒𝑥𝑝 (− )
𝑐𝑊
For cooling using a countercurrent heat sink of equal flow rate and heat capacity
∆𝑇𝑈𝐴𝜏̅𝑐𝑜𝑜𝑙
𝑇𝐻2 = 𝑇𝐻1 −
𝑐𝑊

Problem #5:
(Ex.8.2) A continuous sterilizer with a steam injector and a flash cooler will be employed to sterilize medium
continuously with the flow rate of 2 m3/h. The time for heating and cooling is negligible with this type of sterilizer. The
typical bacterial count of the medium is about 5x1012m–3, which needs to be reduced to such an extent that only one
microorganism can survive during two months of continuous operation. The heat-resistant bacterial spores in the
medium can be characterized by an Arrhenius coefficient (kd0) of 5.7x1039h–1 and an activation energy (Ed) of 2.834x105
kJ/kmol (Deindoerferand Humphrey, 1959). The sterilizer will be constructed with the pipe with an inner diameter of
0.102 m. Steam at 600 kPa(gage pressure) is available to bring the sterilizer to an operating temperature of 125°C. The
physical properties of this medium at 125°C are c = 4.187 kJ/kg·K, ρ= 1000 kg/m3 and μ = 4 kg/m·h.
a. What length should the pipe be in the sterilizer if you assume ideal plug flow?
b. What length should the pipe be in the sterilizer if the effect of axial dispersion is considered?

GIVEN:
Q of medium = 2 m3/ hr
n0 = 5x1012 /m3
n = 1/ 2 mos.
kd0 = 5.7x1039 /hr
Ea = 2.834x105 kJ/kmol
dt = 0.102 m
steam:
P = 600 kPag
T = 125°C
c = 4.187 kJ/kg. °C
ρ = 1000 kg/m3
μ = 4 kg/m.hr

REQUIRED:
a. L of holding tube assuming ideal plug flow
b. L if the effect of axial dispersion is considered

SOLUTION:
a. The working equation to be used in order to solve for L assuming ideal plug flow will be
𝐿
𝜏̅ℎ𝑜𝑙𝑑 =
𝑢̅
𝐿 = (𝜏̅ℎ𝑜𝑙𝑑 )(𝑢)⁡

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In order to solve for 𝜏̅ℎ𝑜𝑙𝑑 ,

𝑛0
∇ℎ𝑜𝑙𝑑 = ln = 𝑘𝑑 𝜏̅ℎ𝑜𝑙𝑑
𝑛
5.7𝑥1039 −2.834𝑥105 375.2590
𝑘𝑑 = ( ) exp ( )=
ℎ𝑟 (8.314)(125 + 273.15) ℎ𝑟
12 3
5𝑥10 𝑚 24ℎ
( ) (2 ) ( ) 375.2590
𝑚3 ℎ𝑟 1⁡𝑑𝑎𝑦
ln =( ) (𝜏̅ℎ𝑜𝑙𝑑 )
1 1⁡𝑚𝑜𝑛𝑡ℎ ℎ
( )( )
2⁡𝑚𝑜𝑛𝑡ℎ𝑠 30⁡𝑑𝑎𝑦𝑠
𝜏̅ℎ𝑜𝑙𝑑 = 0.0991⁡ℎ𝑟𝑠

For u, by dimensional analysis

𝑚3
𝑄⁡𝑜𝑓⁡𝑚𝑒𝑑𝑖𝑢𝑚 2 𝑚
𝑢= =𝜋 ℎ𝑟 = 244.7596
𝐴 (0.102⁡𝑚)2 ℎ𝑟
4
Therefore,
𝑚
𝐿 = (0.0991⁡ℎ𝑟𝑠) (244.7596 )
ℎ𝑟
𝐿 = 24.2557⁡𝑚

b. Upon considering the effects of axial dispersion, it starts with solving Re

𝑚 𝑘𝑔
𝑑𝑡 𝑢𝜌 (0.102⁡𝑚) (244.7596 ℎ𝑟) (1000 𝑚3 )
𝑅𝑒 = = = 6241.3698 ≈ 6.2𝑥103
𝜇 𝑘𝑔
4
𝑚. ℎ

𝐷
Using Fig. 8.4 (from book): @⁡𝑅𝑒 = 6.2𝑥103 ⁡;⁡⁡ ≅ 0.8
𝑢𝑑𝑡
𝑚
𝐷 = (0.8) (244.7596 ) (0.102⁡𝑚)
ℎ𝑟
𝑚2
𝐷 = 19.9724
ℎ𝑟

Then,
1 1⁡𝑚𝑜𝑛𝑡ℎ
𝐶𝑛 ( )( )
2⁡𝑚𝑜𝑛𝑡ℎ𝑠 30⁡𝑑𝑎𝑦𝑠
= = 6.9444𝑥10−17
𝐶𝑛0 5𝑥1012 𝑚3 24ℎ
( ) (2 ) ( )
𝑚3 ℎ𝑟 1⁡𝑑𝑎𝑦
𝑢𝐿 (244.7596)(𝐿)
𝑃𝑒 = = = 12.2549𝐿
𝐷 19.9724
4𝑘𝑑 𝐿 4(375.2590)(𝐿)
𝜁 = √1 + = √1 + = 1.2249
𝑢⁡𝑃𝑒 (244.7596)(12.2549𝐿)
4𝜁 exp(0.5𝑃𝑒)
𝐶′𝑛 =
(1 + 𝜁)2 exp(0.5𝜁𝑃𝑒) − (1 − 𝜁)2 exp(−0.5𝜁𝑃𝑒)
4(1.2249)exp⁡(0.5)(12.2549𝐿)
6.9444𝑥10−17 =
(2.2249) exp(0.5) (1.2249)(12.2549𝐿) − (0.2249)2 exp⁡(−0.5)(1.2249)(12.2549𝐿)
2

𝐿 = 26.9913⁡𝑚
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