Design of Biological Reactor

Module 4
Part 1

Dr. Ariel V. Melendres

 Fed-Batch Reactors
Ø During the course of incubation a particular nutrient is added at intervals without
removing the used up media, so the volume of culture increases continuously.
Ø Such nutrients are kept in lower concentration initially and it is added slowly and
continuously during the course of fermentation to prevent substrate inhibition.
!
(𝑉𝑐# ) = 𝑉𝑟$! (Batch) !
(𝑉𝑐# ) = 𝑉𝑟$! + 𝐹𝑐#$
!"
!"
!
(𝑉𝑐# ) = 𝑉𝑟$! + 𝐹 𝑡 𝑐#$ (Fed-batch) !%! !&
!"
𝑉 +𝑐# = 𝑉𝑟$ + 𝐹𝑐#$
!" !"
i Refers to any component
𝐹 𝑡 = @low rate at any time → 𝐹 (l/h) !$!
𝑉 !#
+𝑐% 𝐹 = 𝑉𝑟&! + 𝐹𝑐%&
rf = rate of formation: g/l-h
V = culture volume: (l)
!$! '
𝐹 𝑐#$ = " (𝑐%& − 𝑐% ) +𝑟&
If density of liquid does not !#
change with time,

!" Cell concentration at any time, 𝑡

!#
=𝐹
V ci
𝑥 = 𝑥+ + 𝑌,/. (𝑠/ − 𝑠)
 Fed-Batch Reactors
BC When the substrate is totally consumed,
BD
= 𝐹 s= 0, x = xm
𝑉 = 𝑉𝑜 + 𝐹𝑡 !)
quasi steady state
!#
= 𝜇−𝐷 𝑥=0
K* xt = total biomass, g '"#$ (
𝑥= C
𝜇=𝐷 µ= )% *(

𝑑𝑥 " " (𝑑𝑉 ) s=

+)%
𝑑𝑥 𝑉( ) − 𝑥
= 𝑑𝑡 𝑑𝑡 '"#$ ,+
𝑑𝑡 𝑉 2

Substrate balance
𝑑𝑥 " !& 𝑑𝑠 " 𝜇𝑥 "
= 𝜇𝑥 " , = 𝐹 = 𝑉𝐷 = 𝐹𝑠$ − 𝑠 & = total amount
𝑑𝑡 !" 𝑑𝑡 𝑌-/( of substrate

𝑑𝑥 𝑉(𝜇𝑥 " ) − 𝑥 " (𝑉𝐷) At quasi steady state

=
𝑑𝑡 𝑉2
!- '- ' ,- ' + -" 𝑑𝑠 "
= = (𝜇 − 𝐷)
!" & & =0
𝑑𝑡
𝑑𝑥 𝜇𝑥 "
= 𝜇−𝐷 𝑥 𝐹𝑠$ =
𝑑𝑡 𝑌-/(
 Fed-Batch Reactors
𝑠 = 0, quasi steady state
Integrating…..
!- ' !&
= 𝑥𝑚 = 𝑥𝑚𝐹 = 𝐹𝑌-/( sf
!" !"

𝑥𝑚 =maximum cell concentration 𝑡

𝑝# = 𝑝.# +𝑞+ 𝑥𝑚 𝑉. + 𝐹 𝑡
Integrating… 2

𝑥 " = 𝑥0" + 𝑡𝐹𝑌-/( 𝑠$ "$ 2% )& "0#

𝑝= 𝑝. " + "
(𝑉. + 1 )t
Product profiles in a fed-batch culture
"$ " 0#
@quasi steady state, s<<sf 𝑝 = 𝑝. + 𝑞+ 𝑥/ ( $ + )t
" " 1

𝑝 = 𝑌+/- (𝑠& -s)= 𝑌+/- 𝑠&

𝑑𝑝# where qp=specific product

= 𝑞+ 𝑥 # formation (g product/gcell-h)
𝑑𝑡

𝑥 " = 𝑥𝑚(𝑉0 + 𝐹𝑡)

𝑑𝑝#
= 𝑞+ 𝑥𝑚(𝑉. + 𝐹𝑡)
𝑑𝑡
Repeated fed-batch culture.
-Part of the culture volume is removed at certain
intervals

V0 is the residual cul- ture volume after removal,

"$ " 0#
𝑝 = 𝑝. "
+ 𝑞+ 𝑥/ ( "$ + 1
)t
Example: In a fed-batch culture operating with intermittent addition of glucose
solution, values of the following parameters are given at time t = 2 h, when the system
is at quasi-steady state.
V = 1000 ml
a)Find V0 (the initial volume of the culture).
so =100 g/l
b)Determine the concentration of growth-limiting substrate in F = dV /dt= 200 ml/h
the vessel at quasi-steady state. 𝜇()* = 0.3/h
c)Determine the concentration and total amount of biomass in Ks = 0.l g/l
the vessel at t = 2 (at quasi-steady state). 𝑌*/, = 0.5g/g
d. If qP = 0.2 g product/g cells-h, po = 0, determine the
concentration of product in the vessel at t = 2 h. 𝑥-& =30 g

Solution c)
𝑥 " = 𝑥0" + 𝐹𝑌-/( 𝑠0 t
𝑎)
𝑥 " = 30 + 0.2 ∗ 0.5 ∗ 100 ∗ 2 = 50 𝑔
𝑉 = 𝑉𝑜 + 𝐹𝑡
-' 45
𝑥2 = = =50g/l
𝑉𝑜 = 𝑉 − 𝐹𝑡 &. *3" 5.7*5.8∗8

𝑉𝑜 = 1000 − 200 2 = 600𝑚𝑙 or

𝑥2 = 𝑌𝑥/𝑠𝑠𝑓 = 0.5(100)=50g/l
b)
D=F/V = 200/1000=0.2/h d) "$ 0#"
𝑝 = 𝑝. "
+ 𝑞+ 𝑥/ ( "$ +
1
)t
[\3
s= 𝑝=
788 8.1(1)
0 + 0.2 (50)(9888 + 1 )2
]456^[
_.a(_.b)
= 16g/l
s= _.c^_.a
= 0.2g/l pt =p (V)= (16g/l)(1l)=16 g
Sample Problem - Repeated fed-batch culture
A fed-batch repeated culture is carried out using the same
condition as in the previous slide, calculate the following:
a) g
b) tw V = 1000 ml
so =100 g/l
c) pw F = dV /dt= 200 ml/h
𝜇()* = 0.3/h
Ks = 0.l g/l
𝑌*/, = 0.5g/g
𝑥-& =30 g
= 600/1000=0.6

&# ,&0 :555,755

tw= = =2
3 855
2 =
pw=gpo+ 10>
" #
(1-g2)
Dw=F/Vw = 200/1000=0.2/h
8.1(?8)
pw=0.6(0)+ 1(8.1)
(1-0.62)

=16g/L
 c)
Solution
𝑥2 = 𝑥𝑜 + 𝑌𝑥 /𝑠𝑠𝑓 = 20𝑔/𝐿 + 0.3 300 g/L=110g/2L=55 g/L
𝑎)
𝑥 " = 𝑥0" + 𝐹(𝑌-/( 𝑠𝑓)t
𝑉 = 𝑉𝑜 + 𝐹𝑡 x ; = 20 ∗ 500 + 50 ∗ 0.3 ∗ 300 ∗ 10 = 55,500g
𝑉 = 500 + 50 10 = 1000 or -' 44455
𝑥2 = = =55g/l
&. *3" 455*45∗:5
b)
d) 𝑝 = 𝑝. "$ + 𝑞+ 𝑥/ ("$ + 0#)t
" " 1
D=F/V = 50/1000=0.05/h
455 455 5.54(:5)
𝑝 = 0.1( ) + 0.05 (55)( + )10=20.675g/L
[\3 :555 :555 8
s=
]456^[ pt =p (V)= (20.675)*1000=20,675 g
_._h(_.h)
s= _.a^_._h
= 0.167g/l
Note: Problem 9.4 (Shuler and Kargi)
For repeated fed-batch culture of the same problem in 9.4 (Shuler and Kargi)
A fed-batch repeated culture is carried out using the same
condition as in the previous slide, calculate the following:
a) g
b) tw
c) pw

= 500/1000=0.5

&# ,&0 :555,455

tw= = = 10 ℎ𝑜𝑢𝑟𝑠
3 45

Dw=F/Vw = 50/1000=0.05/h
2 =
pw=gpo+ 10>
" #
(1-g2)
8.8?(??)
pw=0.5(0.1)+ 1(8.8?)
(1-0.52)

=20.675g/L
 Non-sterile CSTR-Single Bioreactor
BK@
0= At steady state
BD

𝐹𝑥_ − 𝐹𝑥b + 𝜇𝑥b 𝑉 = 0

𝐹(𝑥b −𝑥_ ) = 𝜇𝑥b 𝑉

𝐹
(𝑥b −𝑥_ ) = 𝜇𝑥b
𝑉
𝐷(𝑥b −𝑥_ ) = 𝜇𝑥b

(𝑥b −𝑥_ )
𝜇=𝐷
𝑥b
𝑑𝑥b 𝑥0
𝐹𝑥_ − 𝐹𝑥b + 𝜇b 𝑉𝑥b = 𝑉 𝜇 = 𝐷(1 − )
𝑑𝑡 𝑥1
𝑥0
𝜇1 = 𝐷1(1 − )
𝑥1
 Multiple Bioreactors CSTR
For n stages
CSTR in Series
𝜇a 𝑥a = D2(𝑥a −𝑥b )

𝜇p 𝑥p = 𝐷p (𝑥p − 𝑥p^b )
𝑟K,p = 𝐷p (𝑥p − 𝑥p^b )
At stage 1 for microorganisms
𝐾( 𝜇: 1
𝑠: = 𝑥9 = 𝑥0 + 𝑌)/- (𝑠. −𝑠9 ) 𝑟K,p = (𝑥p − 𝑥p^b )
𝜇2 − 𝜇: Θp
Material balance at stage 2 for
microorganisms 1
𝑑𝑥a Θp = (𝑥p − 𝑥p^b )
𝐹𝑥b − 𝐹𝑥a + 𝜇a 𝑉a 𝑥a = 𝑉a 𝑟K,p
𝑑𝑡
𝑑𝑥a
𝑉a =0 at steady state Can be solved graphically (area
𝑑𝑡 under curve)
𝜇a 𝑥a = D2𝑥a − 𝐷2𝑥b
𝑥b
𝜇a = D2(1 − ).
𝑥a
Sample Problem – Multiple Reactors
x0 = 4 g/l
a. so=50g/L
F=500 L/h

CSTR1
p1 = 22 g/l
x1
*$ s1
𝜇= 𝐷(1 − ) D1,
*%
! !"! " $$"%
Yp/x= =0.71=
#!"#" #!"&

A continuous stirred tank fermenter is used to x1 = 35g/l

cultivate cells that follows Monod growth model.
/ 0/1 3405
Five hundred liter per hour is feed with 4g/L of Yx/s= 2! 02 =0.83=4602
cell and 50 g/L of substrate. Growth parameters " ! !

are µmax = 1.5 h-1 and Ks = 2g/L. The yield Yx/s is s1 = 12.65g/l
0.83 and Yp/x, is 0.71. If the outlet product
concentration is maintained at 22 g/L. 𝜇'() 𝑠1
𝜇=
a) Calculate the dilution rate, s, x and the 𝐾* + 𝑠1
volume of the tank
b) If one reactor is added, what is the cell, +.-(+$./-)
substrate, concentration in the first reactor, 𝜇= =1.295/h
$1+$./-
of same volume. What are the volumes of
the two bioreactors. Compare the volumes
obtained using one CSTR and two CSTR 5
1.295= 𝐷(1 − ), D=1.46/h
system. 34

8 466
V= = = 341.97 𝐿
9 :.5<
 ).+()-.5+)
b. 𝜇2 = -.)-.5+
=1.295/h

x0 = 4 g/l (1.295)(35)= 45.325 = 𝐷2[35 − (4 + 0.83 50 − 𝑠1 )]

x1
so=50g/L D1 = D2 (Since V1 = V2)
F=500 L/h s1
D1,
45.325 = 𝐷1[35 − (4 + 0.83 50 − 𝑠1 )] Eq.2

CSTR1 CSTR2
Eq.2÷Eq.1
p2 = 22 g/l 45.325 𝐷1[35 − (4 + 0.83 50 − 𝑠1 )]
x2 = 35 g/l =
1.5𝑠 𝐷1[4 + 0.83(50 − 𝑠1) − 4]
s2 = 12 .65g/l (2 + 𝑠1 )4 + 0.83(50 − 𝑠1)
1
At Reactor 1
D2=?
5 45.325 35 − (4 + 0.83 50 − 𝑠1)
𝜇1 = 𝐷1(1 − ) 1.5𝑠1
=
[4 + 0.83(50 − 𝑠1) − 4]
*%
𝜇120 𝑠1 2 + 𝑠1 [4 + 0.83(50 − 𝑠1)]
𝜇1 =
𝐾, + 𝑠1
1.5𝑠1
s1=39.15 g/L
𝜇1 = 𝑥1 = 4 + 0.83(50 − 𝑠1)
2 + 𝑠1
).+,! / 𝑥1 = 4 + 0.83(50 − 39.15)
-.,!
= 𝐷1(1 − 0 ) =13.00 g/L
#

𝑥1 = 𝑥7 + 𝑌0/, (𝑠7 − 𝑠1) 45.325 = 𝐷1[35 − (4 + 0.83 50 − 𝑠1 )]

𝑥1 = 4 + 0.83(50 − 𝑠1) 45.325 = 𝐷1[35 − (4 + 0.83 50 − 39.15 )]

).+,! /
-.,!
= 𝐷1(1 −
/.9.:; (+9<,!)
) D1=2.06 h-1
= +99
1.5𝑠1 V1=> = -.95=242.72 L
[(4 + 0.83(50 − 𝑠1)] = 𝐷1[4 + 0.83(50 − 𝑠1) − 4]
2 + 𝑠1 Eq. 1 !
V2=242.72 L
At Reactor 2 VT = V1+V2=242.72+242.72=485.44
0 L
𝜇2 = 𝐷2(1 − 0 !)
$ % Volume difference = (Vtwo – Vone)/Vone x100=
5L6.M3(460,!)
𝜇2 = 𝐷2(1 − 34
)
(485.44-341.97)/341.97x100=41.97%
Batch or Plug Flow Fermenter

Plug flow fermenter (PFF) is an ideal tubular-flow fermenter

without variations in radial direction.

The cell concentration of an Ideal Batch Fermenter after time t is

the same as the that of steady state PFF with residence time
same as time Θ or t .

The graphical procedures adopted in both cases are similar as

shown by the material balance wherein the main difference is
that the residence time in the case of the plug-flow reactor is
replaced by the actual time t for batch reactor.
 Plug Flow Bioreactor/Fermenter
PFTR: Plug Flow Tubular Reactor
PFF: Plug Flow Fermenter
In a tubular-flow fermenter, nutrients and microorganisms enter one end of a
cylindrical tube and the cells grow while they pass through.
However, the variation in the radial direction is small compared to that in the longitudinal
direction. The ideal tubular-flow fermenter without radial variations is called a plug-flow
fermenter (PFF). .
Z Z+Dz

u u
uc Z uc Z+Dz

Z=0 Auc z - Auc z+Dz + ADz𝑟$% z = 0 Z=L

u liquid velocity (m/s)

Z length (m) uc z+Dz
- uc z
A cross sectional area (m2) = 𝑟$%
c concentration (g/l) Dz
𝑟?@ rate of formation of c
! !%
𝑢 (c)= 𝑟$% = 𝑟$%
!? !"
 Tubular Plug Flow

𝑐 𝑐 + ∆𝑐
x0 x1
so s1
F F

Same equation as
in Batch
𝑉𝑑𝑐
= 𝑉𝑟NO In general
𝑑𝑡

𝑑𝑥
𝑌(𝑠0 − 𝑠) = 𝑥 − 𝑥5
= 𝜇𝑥 For microorganism 𝑥 = 𝑥5 + 𝑌(𝑠0 − 𝑠)
𝑑𝑡

𝑑𝑥 𝜇()* 𝑠 ds − µ34# s
= 𝑥 = [x + Y(s6 − s)]
𝑑𝑡 𝐾, + 𝑆 dt Y (K 5 +s) %
𝑥 − 𝑥5 Integrate with limits of
𝑌-/( =𝑌=
𝑠0 − 𝑠 t = 0, s = s0,
t = t, s = s,
𝑌(𝑠2 − 𝑠) = (𝑥 − 𝑥% )
𝑑𝑠 𝑑𝑥 𝑥% + 𝑌(𝑠2 − 𝑠) 𝑠
−𝑌 = 𝑥% + 𝑌(𝑠2 + 𝐾* )ln − 𝐾* 𝑌ln = 𝜇'() 𝑡(𝑥% + 𝑌𝑠2 )
𝑑𝑡 𝑑𝑡 𝑥% 𝑠2
𝑑𝑠 −1 𝑑𝑥
=
𝑑𝑡 𝑌 𝑑𝑡
𝑑𝑠 −1 𝜇120 𝑠
= 𝑥
𝑑𝑡 𝑌 𝐾, + 𝑠
Example
The growth rate of E. coli can be expressed by Monod kinetics with the
parameters of µmax =0.935/h and KS =0.71 g/L. Assume that the cell yield is 0.6 g dry cells
per g substrate. If xo is 1 g/L and so 10 g/L when the cells start to grow exponentially, at t =
0, show how x, s, change with time.
a) What is the cell and substrate concentration after 1, 1.5 hours?
b) At 20%, 50% and 70% substrate conversion, what is the residence time (for PFF) and
time t for batch cultivation
c) Plot conversion vs time
d) Using the plot, find the residence at 70% and 80% substrate
conversion
µmax =0.935/h Substrate
KS =0.71 g/L conversion (-) s (g/L) x (g/L) t (h)
YX/S = 0.6 dry cells per g substrate 0.0 10.0 0.00 0.00
xo = 1 g/L 0.1 9.0 0.60 0.54
so = 10 g/L 0.2 8.0 1.20 0.91
0.3 7.0 1.80 1.19
Solution 0.4 6.0 2.40 1.42
0.5 5.0 3.00 1.62
𝑥 = 𝑥5 + 𝑌(𝑠0 − 𝑠) 0.6 4.0 3.60 1.79
𝑥6 + 𝑌(𝑠- − 𝑠) 𝑠 0.7 3.0 4.20 1.95
𝜇()* 𝑡(𝑥6 + 𝑌𝑠- ) = 𝑥6 𝑌(𝑠- + 𝐾, )ln + 𝐾, 𝑌ln 0.8 2.0 4.80 2.10
𝑥6 𝑠-
0.9 1.0 5.40 2.26
 𝑥6 + 𝑌(𝑠- − 𝑠) 𝑠
𝜇()* 𝑡(𝑥6 + 𝑌𝑠- ) = 𝑥6 +𝑌(𝑠- +𝐾, )ln + 𝐾, 𝑌ln
𝑥6 𝑠-
12.00

10.00

8.00
s
s or x(g/L)

6.00

4.00

2.00
x
0.00
0.00 0.50 1.00 1.50 2.00 2.50
time (h)

x (g/L) s (g/L)

Change of x and s with time

Batch or Plug Flow Fermenter

Residence time (Θ) for plug-flow reactor

Actual time t for batch reactor.
 Example Bioreactors in Series
Suppose you cultivate microorganism that obeys the Monod equation where µmax =0.7hr-1 and Ks = 5
g/L. The cell yield (Yx/s) is 0.65. You want to cultivate this microorganism in either one fermenter or two
in series. The flow rate and the substrate concentration of the inlet stream should be 500 L/hr and 85
g/L, respectively. The substrate concentration of the outlet stream must be 5 g/L.
a) If you use one CSTF, what should be the size of the fermenter? What is the cell concentration of
the outlet stream?
b) If you use two CSTFs in series, what sizes of the two fermenters will be most productive? What are
the concentration of cells and substrate in the outlet stream of the first fermenter?
c) If a PFF is used after the CSTF, what is the size of the PFF and what are the
concentration of cells and substrate in the outlet stream?
Solution:
a) One CSTF b) Two CSTF, first reactor is optimized
At first reactor
:* -
Dopt=µmax(1- ) =0.7(1− )=0.535
so=85g/L :*1*8 -1;-

+)( 5.4@4(4)
s= = =16.21 g/L
'120 ,+ 5.A,5.4B4
=5g/L
xopt=Yx/s(sf-s) =0.65(85−16.21)=44.71
' A&WX - 8.E(?)
D=" = = ?C? = 0.35/ℎ Or
BY CD xopt= 𝑌)/* ( 𝑠8 + 𝐾𝑠)(1 −
9&
)
9 & 15'
' ?88
V = 0 = 8.F?= 1428. 57𝐿 4
xopt= 0.65( 85 + 5)(1 − ) = 44.71
4LM4
The cell concentration of the outlet stream is
Since x is larger than xopt , need two reactors in series.
x =Yx/s(sf – s)= 0 .65 (85 - 5) =52 g/L
At the second stage
𝑉𝑇 = 𝑉1 + 𝑉2
= 934.58 + 200.8 = 1135.38𝐿

This value is less than that of single

reactor of V=1429L by about 20%

𝑥: (𝑉𝑇 − 𝑉)/𝑉𝑇 =
𝜇8 = D2(1 − ). =(1428.57 − 1135.38)/1428.57 x100
𝑥8 = 20%
𝜇()* 𝑠2 0.7(5)
𝜇P = )= = 0.35/ℎ
(𝐾𝑠 + 𝑠2 5 + 5)

<( %.=-
𝐷$ = ) = =2.49 /h
(+" * ) +"&-/-$
)(

𝐹 500𝑙/ℎ
𝑉2 = = = 200.8𝐿
𝐷2 2.49/ℎ
 For the second stage using PFF
umax 0.7 1/h
Ks 5 g/L
sf 85 g/L
F 500 L/h
Yx/s 0.65
F
x1
s1 F
x2
s2

𝑥6 + 𝑌(𝑠- − 𝑠) 𝑠
𝑥6 + 𝑌(𝑠- + 𝐾, )ln + 𝐾, 𝑌ln = 𝜇()* 𝑡(𝑥6 + 𝑌𝑠- )
𝑥6 𝑠-

𝑥: + 𝑌(𝑠: − 𝑠2) 𝑠2
𝑥: + 𝑌(𝑠: + 𝐾, )ln + 𝐾, 𝑌ln = 𝜇()* 𝑡(𝑥: + 𝑌𝑠: )
𝑥: 𝑠:
A
𝑠) = 16 B
A
𝑠- = 5 B
x1= 45g/l

Using the above equation for plug Wlow fermenter 𝑉𝑇 = 𝑉1 + 𝑉2

= 934.58 + 160 = 1094.58𝐿
𝑡 = 0.32h
D=1/0.32 = 3.125 (𝑉𝑇 − 𝑉)/𝑉𝑇 =
=(1428.57 − 1094.38)/1428.57 x100
V= F/D = 500/5= 160L
= 23.4%
 Single Bioreactor or Multiple Bioreactors
connected in Series

F
x1
s1
F
x2
s2
(a) (b) (c)

(a) If the final cell concentration is less than xopt ,

one fermenter is better than two fermenters in series,
(b) and (c) If the final cell concentration is larger than xopt, the best combination is
CSTF followed by another CSTF or PFF
 Sample Problem Bioreactor: Single or Multiple
A certain microorganism obeys the Monod equation where For two stage reactor,
µmax =0.5hr-1 and Ks = 2 g/L. The cell yield Yx/s is 0.4. The flow First reactor is at optimum
rate and the substrate concentration of the inlet is 200 L/hr and Second reactor is evaluated using outlet condition
50 g/L, respectively. It is designed exit substrate conc. is 15 g/L
a) If you use one CSTF, what should be the size of the so=50g/L
fermenter? Wat is the cell concentration of the outlet stream?
b) If run with two CSTF, with the first one optimized, compare
the volume with a) s2=15g/L

(a) One CSTF First reactor

Dopt=µmax(1-
V, P
so=50g/L ) =0.5(1− )=0.402
V,L,N PL46

=15g/L 9V, 6.56P(P)

s= = =8.204 g/L
W$%& 09 6.406.56P

For a single steady-state CSTRFwith a sterile feed, the dilution xopt=Yx/s(sf-s) =0.4(50−8.204)=16.72
rate is equal to specific growth rate:
Second reactor
3 '"#$ ( 5.4(:4) 𝜇()* 𝑠2 0.5(8)
D= = = = 0.441/ℎ 𝜇P = = ) = 0.4/ℎ
& )% *D 8*:4 (𝐾𝑠 + 𝑠2) (2 + 8
<( %.&
𝐷$ = ) = =-2.059 /h
3 855 (+" * ) +"+/.>$/+&
V= = = 543.51 𝐿 )(
+ 5.@@:
Not possible!!!
The cell concentration of the outlet stream is Since, the x concentration at the second recorder
x =Yx/s(sf – s)= 0 .4 (50- 15) =14 g/L exceeds the design concentration at first reactor,
second reactor is not needed. Why will you spend
Check if x=14 g/L is than less or more money of putting a second recorder if you already
reached your target with one reactor.
than xopt
Sample Problem Bioreactor: Single or Multiple
A certain microorganism obeys the Monod equation where µmax =0.5hr-1 and Ks = 2
g/L. The cell yield Yx/s is 0.4. The flow rate and the substrate concentration of the inlet
is 600 L/hr and 50 g/L, respectively. The substrate at the exit tank is 96% converted
a) If single CSTF is used what is the size?
b) If two CSTFs (firs is optimized) are used what is the size of each?
c) If one CSTF followed by PFF (in series) are used what is the size of each?

(a) One CSTF

so=50g/L

=50(1-0.96)=2g/L

a. One CSTF
s=50(1-0.96)=2g/L

x=0.4(50-2)=19.2g/L
' A&WX - 8.?(1)
D=" = BY C-
= 1C1 = 0.25/ℎ
3 855
V= = = 800 𝐿
+ 5.84

The cell concentration of the outlet stream is

 b) For two stage reactor, (2 CSTFs)
First reactor is at optimum
Second reactor is evaluated using outlet condition WC 6.P4
𝐷P = D = :0:<.XP/:Y.P=1.94 /h
(:0 % )
DC
x1= 16.72𝑔/𝐿
8 P66
V2 = 9 = :.Y5= 103 𝐿
'

so=50g/L s2=2g/L 𝑉𝑇 = 𝑉1 + 𝑉2
x2=19.2g/L = 496.28 + 103 = 600𝐿

No. of Stage V1 CSTF) V2 (CSTF) VT

First reactor 1-Stage 800 L 0L 800L

V, P
2-Stage 496.3 L 103L 600L
Dopt=µmax(1- V,L,N
) =0.5(1− PL46
)=0.402

9V, 6.56P(P)
s= = =8.204 g/L (𝑉 − 𝑉𝑇 )/𝑉𝑇 =
W$%& 09 6.406.56P
=(800 − 600)/800 x100
= 25% smaller if 2 CSTF are used
xopt=Yx/s(sf-s) =0.4(50−8.204)=16.72
Since x2 is larger than xopt , two reactors are needed
8 P66
V1 = 9 = 6.56P= 496.28 𝐿
!

Second reactor
𝜇()* 𝑠2 0.5(2)
𝜇P = = ) = 0.25/ℎ
(𝐾𝑠 + 𝑠2) 2+2
 c) For two stage reactor (CSTF + PFF) No. of Stage V1 CSTF) V2 (PFF) VT
First reactor is at optimum
Second reactor is evaluated using outlet condition 1-Stage 800 L 0L 800L

2-Stage 496.3 L 80L 576 L

F (𝑉 − 𝑉𝑇 )/𝑉𝑇 =
x1 =(800 − 576)/800 x100
s1 = 28% smaller: (if 2 CSTF’s are used)
F
x2 Rank (From worse to best
s2 1. CSTF+PFF (576 L)
(𝑥: + 𝑌(𝑠: + 𝐾, ))ln
*% + ^(,% 0,') ,
+ 𝐾, 𝑌ln , ' = 𝜇()* 𝑡(𝑥: + 𝑌𝑠: ) 2. CSTF+CSTF (600 L)
*% %
3. CSTF (800 L)
A
𝑠) = 8.204 B
A
𝑠- = 2 B
x1= 16.72g/l

Using the above equation for plug Wlow fermenter

16.72 + 0.4 8.204 − 2 2
(16.72 + 0.4(8.204 + 2))ln + 2(0.4)ln = 0.5𝑡(16.72+ 0.4(8.204))
16.72 8.204
𝑡 = 0.4h
D=1/0.4 = 2.5

V= F/D = 200/2.5= 80L