In the fermentation plant, large-scale air compressor is one of the core equipment to ensure the production process, and its role runs through multiple links such as microbial culture, process control, and energy utilization. The following are specific application scenarios and technical analysis:
1. microbial culture oxygen supply
- role: Air compressor for fermentation tank supply clean oil-free compressed air ensure that the microorganisms get enough oxygen during the fermentation process.
- Technical Details:
- compressed air must pass through multistage filtration(including oil removal, dust removal and sterilization) to ensure that the gas quality meets the requirements of the fermentation process.
- Oxygen supply pressure is usually controlled 0.3-3.5bar, depending on the fermentation tank level, back pressure and process requirements.
- Industry case by optimizing the oxygen supply system in an amino acid fermentation plant, the strain yield was increased by 18% and the fermentation period was shortened by 6 hours.
2. process control
- role: Compressed air is used regulation of pressure and flow rate in the fermenter ensure process stability.
- Application Scenarios:
- pressure control by adjusting the output of the air compressor, the pressure in the tank is maintained stable (e. g. 1.8-2.5bar) to avoid pressure fluctuations affecting microbial metabolism.
- ventilation regulation: Adjust the air intake according to the fermentation stage, such as increasing the ventilation during the logarithmic growth period to promote the reproduction of the bacteria.
- Technical advantages: Adopt frequency conversion screw air compressor the gas volume can be adjusted in real time, and the energy saving efficiency is improved by more than 30%.
Cleaning and disinfection of 3. equipment
- role: Utilizing compressed air purging inside of equipment remove residues and reduce the risk of microbial contamination.
- Application Scenarios:
- empty elimination of fermentation tank: Use compressed air to discharge residual steam before sterilization to avoid condensed water affecting the sterilization effect.
- Filter Maintenance: Regularly use compressed air to blow the filter back to extend its service life.
- hygienic standard: Compressed air needs to reach ISO 8573-1:2010 Class 1.4.1 standard (oil-free, water-free, particle-free).
4. waste heat recovery and utilization
- role: The high temperature heat generated by the air compressor (accounting for 85% of the energy consumption) can pass waste heat recovery technology reuse.
- Application Scenarios:
- hot water preparation: Used for heating, bathing or process heating (such as reverse osmosis raw water heating).
- Refrigeration drive: In summer, waste heat is used to drive the lithium bromide refrigerator to cool the fermentation workshop.
- energy saving effect: After a pharmaceutical enterprise adopts waste heat recovery, the annual energy saving cost exceeds 6 million yuan.
5. multi-fermenter synergetic gas supply
- role: Large fermentation plants usually pass. Supply air to the main line, to provide compressed air for multiple fermentation tanks.
- System Configuration:
- flow regulating valve: Each fermentation tank is equipped with a regulating valve to achieve accurate gas supply.
- intelligent joint control: Automatically adjust the number of air compressors according to the fermentation cycle to avoid no-load energy consumption.
- Extensibility: Supports future addition of fermenters, reducing system expansion costs by 40%.
Selection and maintenance recommendations
- equipment selection: Preferred oil-free centrifugal air compressor or frequency conversion screw air compressor to match the fermentation process needs.
- Regular maintenance: Replace the air filter every 2000 hours and check the quality of lubricating oil every quarter.
- Energy efficiency monitoring install smart sensors to track the energy efficiency of air compressors in real time to ensure optimal operating costs.
Through the above comprehensive application, the large air compressor not only guarantees the stability of the fermentation process, but also significantly improves the energy efficiency and helps the fermentation plant to achieve green production.
