The role of fermentation tank with air compressor

Technical Specification and Application Analysis of Air Compressor for Fermentation Tank

in the field of biological fermentation industry, air compressor is the core auxiliary equipment to provide key power support for the fermentation process. In combination with the general technical standards of the industry, the functions, technical requirements and operation and maintenance specifications of the air compressor for the fermentation tank are described as follows:

the core role of 1. air compressor in fermentation process

1. Oxygen supply and dissolution

• function Analysis in aerobic fermentation process, microbial metabolism needs to consume a lot of oxygen. After the air compressor compresses the ambient air, it is injected into the fermentation liquid in the form of tiny bubbles through an aeration device (such as a microporous aeration plate and a jet) to improve the efficiency of oxygen dissolution.
• Technical Requirements according to the volume of fermentation tank and microbial oxygen demand, an air compressor with rated displacement ≥ 1.2 times of theoretical oxygen demand shall be configured to ensure that the dissolved oxygen concentration is stable in the range of 20%-80% saturation.

2. Tank pressure maintenance

• function Analysis: By adjusting the compressed air intake, control the pressure in the fermentation tank (usually 0.05-0.15MPa), prevent miscellaneous bacteria pollution, and optimize the microbial metabolism environment.
• Technical Requirements precision pressure regulating valve and pressure sensor shall be configured to realize tank pressure fluctuation ≤ ± 0.01MPa.

3. Material mixing and mass transfer

• function Analysis compressed air forms an updraft in the fermentation liquid, drives the liquid to circulate, and realizes the uniform mixing of materials and the rapid transfer of heat and dissolved oxygen.
• Technical Requirements according to the viscosity of the fermentation liquor and the ratio of height to diameter of the tank, the layout of the aeration device and the air flow shall be optimized to ensure that the mixing time is less than or equal to 60 seconds.

Technical requirements for 2. air handling system

1. Cleanliness control

• filter Configuration: A primary filter (intercepting ≥ 5μm particles), a precision filter (intercepting ≥ 0.01μm particles) and a sterilization filter (filtration efficiency ≥ 99.999) are arranged in sequence at the outlet of the air compressor to ensure the sterility of the air entering the fermentation tank.
• Sterilization treatment before fermentation, the air pipeline shall be steam sterilized at 121 ℃, and the sterilization cycle shall match the fermentation batch.

2. Temperature and humidity regulation

• cooling dehumidification: Reduce the compressed air temperature to ≤ 40 ℃ through the after-cooler, and cooperate with the gas-water separator to remove the condensed water to avoid water entering the fermentation tank and causing the cell autolysis.
• Heating device: In low temperature environment, air heater shall be equipped to maintain the intake air temperature ≥ 25 ℃ to prevent temperature fluctuation of fermentation liquid.

3. Typical Application Scenarios and Configuration Scheme

1. Antibiotic fermentation

• scene Features strict aseptic environment, long fermentation period (7-14 days), large fluctuations in oxygen demand.
• Configuration Scenario:
  • select oil-free air compressor to avoid oil pollution;
  • configuration of dual head air compressor, automatic switching standby machine in case of single fault;
  • set up on-line dissolved oxygen meter and tail gas analyzer to monitor the fermentation state in real time.

2. Amino acid fermentation

• scene Features: High viscosity fermentation liquid, strong aeration capacity, energy consumption sensitive.
• Configuration Scenario:
  • selection of high pressure than air compressor, improve aeration efficiency;
  • equipped with frequency converter, adjust the air intake according to the feedback of dissolved oxygen, saving energy by 20%-30%;
  • install the silencer and control the noise ≤ 75dB(A).

3. Enzyme Fermentation

• scene Features: Dissolved oxygen and pH need to be precisely controlled, sensitive to shear force.
• Configuration Scenario:
  • the use of low-pulse air compressors to reduce shear damage to the thallus caused by airflow fluctuations;
  • configuration of mass flow meter, accurate control of ventilation ratio (0.5-1.5vvm);
  • set air buffer tank to stabilize the intake pressure.

4. operation and maintenance management specification

1. filter element replacement cycle:
   • check the pressure difference of the precision filter element every 3 months and replace it when it exceeds 0.1MPa;
   • sterilization filter cartridge is replaced after each batch of fermentation.
2. Energy efficiency optimization:
   • regularly detect pipeline leakage, and the energy consumption of air compressor increases by about 5% for every 0.01MPa pressure decrease;
   • implement the peak-valley electricity price strategy, and carry out fermentation tank sterilization and air compressor maintenance during low electricity price periods.
3. Emergency plan:
   • standby air compressor and diesel generator shall be provided to ensure continuous air supply;
   • installation of air compressor fault alarm system, over-temperature, over-pressure automatically shut down and trigger standby equipment to start.

5. Supplementary Provisions

this specification is applicable to the selection, system design and operation and maintenance management of air compressors in fermentation industrial enterprises. When the fermentation of special strains or high value-added products is involved, a special technical scheme should be formulated in combination with the process characteristics and GMP requirements.

By clarifying the functional positioning and technical requirements of the air compressor in the fermentation process, enterprises can optimize the configuration of the fermentation system, improve product yield and production stability, and reduce energy efficiency costs and pollution risks.