Automatic Stainless Steel Jacketed Fermenter Bioreactor

3000L

fermenter

Fermenter body

The size of fermenter takes in general use type as basis and The main material of the fermenter is made by 316L stainless steel. The design pressure: P(inside)= 0.3Mpa, P(interlayer)= 0.3Mpa, The polishing precision: Ra0.4～0.6, the ratio between diameter and height: 1:2.8

Sterilization method

Auto sterilizing in situ(SIP)

Stirring system

Mechanical sealing system at the top of the fermenter; high-powered stirring oar, antifoam oar; AC electrical machine(SEW):  infinite speed variation;  rpm in the 6000L fermenter: 50~300rpm±1%,  infinite speed regulated by transducer. The height of the stirring oar can be adjusted, too.

Temperature detection and control

Heat by thermostatic water tank and circulate by circulating pump(Grundfos, Denmark), autocontrol (cooling water+5℃)~70℃±0.1℃，temperature probe(imported)

pH detection and control

2.00-12.00±0.05pH, autocontrol by adding acid and base, pH sensor (Mettler, Switzerland) and shielding lead (Mettler, Switzerland). 6000L fermenter is autocontrolled with pneumatic diaphragm cell valve(BURKERT, Germany)

DO detection and control

0-150±3% displaying precision 0.1%, sensor (Mettler, Switzerland) and shielding lead(Mettler, Switzerland)

Feed control

3000L fermenter uses pneumatic diaphragm cell valve(BURKERT, Germany).

Antifoam control

Tested by sencor and added antifoamer by peristaltic pump (Longer).

Aeration detection and control

automanual control ventilatory capacity, the precision of nhaler : 0.1μ, displayed by rotameter. The range of flow adjusting of 6000L fermenter: 0~12000L/min

pressure detection and control

autoManual control exhaust by diaphragm cell valve(BURKERT, Germany) and displayed by pressure gauge.

Pipeline and valve

The pipelines and valves which are in contact with the zymotic fluid are made by 316L stainless steel, the valves are diaphragm cell valves(BURKERT, Germany).

Control system

Control System: on-site controller, the next crew for the Siemens S7-200 series PLC control system, it is a mature, stable, universal type of PLC, to suit a variety of automation applications, especially in manufacturing process control Application. Its modular, easy to implement distributed configuration and easy to master and so on, Siemens PLC control center has become a biological reaction process control implementation is economical and advanced control system, the system uses the touch screen display, on-site direct operations (menu type), all English menu and interface; also with the host computer for data transmission, data sampling and display tank, the system view of data analysis, reading settings.

10-inch LCD touch-sensitive screen as the display screen to display complete content-rich, user-friendly screen is simple, easy to operate. And disturbing each other. The control system can adapt to different range of sensors and actuators the output of the input signal with the signal anti-jamming system.

Software: Siemens S7+  FORCE  CONTORL

Data collection and control module: Siemens S200 PLC controller and data collection and control module

1. Control
① Manual control: You can set the percentage of open valve or a valve opening ② automatic control mode: You can select continuous or PID, PID control the switch ③ sequence control: the control of all parameters can be pre-set at least 10 control section, ④ for automatic segmentation remotely control: PC control ⑤ acceptable correlation control: the dissolved oxygen can select speed, air flow rate, tank pressure, control of feeding, etc.; pH can choose to control with acid and alkali

2. Measurement function: can feeding, bubble enemy, such as measurement of pH

3. XY-axis to chart real progress can be any expansion and contraction of graphics display, to help the operator determine the parameters of the interaction between the effects of the fermentation process to quickly modify and adjust

4. Data Processing
1) to show that all the parameters of the trend curve analysis
2) to store, display, analyze all the historical curve parameters
3) can display all the parameters of the batch report
4) copy the data directly with the USB

5) data storage format is compatible with EXCEL, EXCEL platform can be to deal with

5. Controller self-protection function: to set the password, others can not modify the fermentation

parameters; and the controller is not lost due to power settings for each parameter
6. Can the process control parameters, each parameter can have 10 block can be set
7. Time display of each parameter recording interval can be adjusted
8. Two parameters can be carried out with the screen settings and calibration

9. show the controller is really running against, the panel instructed the state process system, process hardware, and motion status indicator for understanding the various devices (such as peristaltic pumps, circulating pumps, heating, mixing, etc.) work status, Fault identification can be used as display
10. Each parameter of the transmission are independent modules, without disturbing each other, for easy maintenance
11.PH, DO and other parameters of control and associated controls can be adjusted

PC software

Control Software Ver8.0 is a data recording and processing as one of the fermentation of special packages, with the Chinese operation interface, data storage and backup, curve analysis, report generation analysis, anomaly analysis, for the fermentation and production process control and data processing bring a lot of convenience.
Main features:
1. Can record the fermentation time, temperature, pH, dissolved oxygen, rotational speed, air flow, pressure; fill quantity, the amount of foam enemy, acid dosage
2. Can be sent under the controlled variable settings and control parameters, remote operation
3. Can be set sequence control
4. Can type off-line parameters, and records show
5. Trend curve, historical curve shows
      can display 1-10 (any setting) curve;
-    You can select a different start time and the time period (8,24,48,72,96 and 144 hours);
-    You can set the upper and lower curves show, in order to improve display resolution;
-    You can choose any of several different batches (1-10) curve also shows that for comparative analysis;
-    and Y-axis parallel to the secant by the mouse to drag the reading, followed by curve data is activated, the fermentation time (X axis) and the same time the data curve with the secant movement changes;

 6. Report Printing
- can show significant 1-12 (any set) data, and print output;
- You can select a different start time and the time and can choose different time intervals (1,5,15,30,60 minutes);
- You can choose any of several different batches (any set) data, and print output,
- To comparative analysis;

 7. curve printing
- You can show the curve was printed by color printer;
EXCEL platform can also be carried out in data processing and printing, is very convenient.

1

pH

Displaying range: 0.00~14.00±0.01

Auto-control range:2.00~12.00±0.05

Fermentation process control (According to the fermentation time, auto- control pH fluent, at least10 parts)

pH value historical and trend curve analysis

Acid, alkali dosage curve analysis

Batch report form analysis

Acid, alkali total dosage record

Keep and deliver data

2

DO

0-150±3％，Displaying precision: 0.1％

It can be controlled by rev and feeding.

Fermentation process control (According to the fermentation time, auto- control DO fluent, at least10 parts)

DO value historical and trend curve analysis

Batch report form analysis

Keep and deliver data

3

Antifoam

Automatic PID control and alarm

Fermentation process control (According to the fermentation time, auto- control antifoam fluent, at least10 parts)

Antifoam value historical and trend curve analysis

Foam error state record

antifoam total dosage record

Batch report form analysis

Keep and deliver data

4

Rev

Automatic enactment and control

Fermentation process control (According to the fermentation time, auto- control rev fluent, at least10 parts)

Rev value historical and trend curve analysis

Batch report form analysis

Keep and deliver data

5

Temperature

Temperature of cooling water: +5℃-70℃±0.1℃

Fermentation process control (According to the fermentation time, auto- control temperature fluent, at least10 parts)

Temperature value historical and trend curve analysis

Batch report form analysis

Keep and deliver data

6

Feeding

PID automatic enactment and control

Fermentation process control (According to the fermentation time, auto- control feeding fluent, at least10 parts)

Feeding value historical and trend curve analysis

Feeding total dosage record

Batch report form analysis

Keep and deliver data

7

Pressure

Manual control, instrument display

8

Air flux

Manual control, instrument display

Impellers

Standard : Turbine impeller and Foam breaker (316L stainless steel)

Control

Inverter

Materials & Finish

Vessel

Using 316L stainless steel to polishing.

Piping

316L stainless steel to prevent contamination.

O-rings / Gaskets

Viton or silicone material is used for the O-ring

and the EPDM is used for gasket.

Power Supply

Controller system : 220V 50/60Hz, single phase

Fermentor system : 440V~220V 50/60Hz, single and/or three phase

Data Storage

pH, DO, Pressure, Temperature and Agitation speed

Working Vol.

700L

1000L

1500L

2000L

3500L

7000L

Dia. : Height

1:2

1:2

1:2

1:2

1:2

1:2