Impellers

Two types of impellers are commonly used in industrial fermentation processes.

Propeller agitators resemble marine propellers, with the main difference being that
in industrial use, the vessel remains stationary while the fluid moves. Axial
impellers are similar to radial ones, except that the blades are pitched, generally at
a 45 degree angle. This causes flow to move downward parallel to the shaft, and
then up along the wall of the tank. They are generally installed vertically in a tank,
so as to allow for the fluid to circulate in one direction along the axis, while going
in the opposite direction along the walls. Propellers are generally only employed in
small-scale applications where their flexibility is desirable. They are often used to
disperse gases or non-wetting solids in liquids due to the deep vortex they are able
to create. They generally have diameters of not greater than 1.5 meters, and are
characterized by their high rotational speed. They may range in power from those
of laboratory size up to 50 kW. This type of impeller also serves as a means to
achieve bulk mixing and produce a homologous sample. The accompanying figure
shows both a picture and the circulation pattern associated with this type of
impeller.
The second type is a turbine impeller. Turbine impellers are mounted on shafts like
propellers, but are usually much larger, and rotate at slower speeds. Turbines,
because they are available in many impeller designs, are more flexible and efficient
than propellers in several ways. Radial-flow impellers are similar to centrifugal
pumps, in that they discharge liquids at high velocities in the radial direction. This
acts like a jet mixer, causing entrainment of the surrounding fluid, while setting up
two circulation systems. One of these is above the impeller, the other below.
Liquid flowing outward separates at the wall, with some flowing up to the surface
and returning to the eye of the impeller along the shaft. The remainder flows down
along the wall, across the bottom of the tank, and returns back to the center of the
impeller. Practical turbine impellers are limited to approximately 5 meters in
diameter, translating to multiple tanks or multiple agitators necessary for larger
plant capacities. In Fermentation plants, these impellers serve the purpose of
creating mass transfer in order to break up oxygen bubbles. The high shear
associated with the impeller necessitates a power demand 10-15 times that of the
propeller-type impeller. The accompanying figure again shows a picture and the
circulation pattern associated with this type of impeller
Impellers in agitated tanks are used to mix fluids or slurry in the tank. This can be used to
combine materials in the form of solids, liquids and gas. Mixing the fluids in a tank is very
important if there are gradients in conditions such as temperature or concentration.
There are two types of impellers, depending on the flow regime created (see figure):

Axial flow impeller

Radial flow impeller

Radial flow impellers impose essentially shear stress to the fluid, and are used, for example, to
mix immiscible liquids or in general when there is a deformable interface to break. Another
application of radial flow impellers are the mixing of very viscous fluids.
Axial flow impellers impose essentially bulk motion, and are used on homogenization processes,
in which increased fluid volumetric flow rate is important.
Impellers can be further classified principally into three sub-types

Propellers

Paddles

Turbines

Analysis can be performed in two ways:

withdraw a sample and perform off-line analysis

by integrating the sensor in the process

Off-Line Monitoring

Sample is withdrawn from the bioreactor/vessel and analyzed after sample preparation in a

suitable device. The preparation and handling of the sample is of crucial importance because
it may affect the accuracy of the measurement.

For all off-line samples, detailed procedures, trained staff, and suitable laboratory are
required. Off-line analytics always has a delay and affects the frequency of the
measurement.

In situ or In-Line Monitoring

involves the use of sensors placed directly in the vessel or the flow lines associated with it or
the unit operation (e.g. conductivity or pH monitoring

in purification steps).

The use of in situ sensors are well established, especially for chemical or physical parameters
(pH, redox potential, O2, CO2, conductivity, and turbidity).

In Situ monitoring allows rapid measurement in high frequency and therefore enables realtime measurement and direct control. Robustness, long-term stability, aseptic design, and
SIP/CIP capability are a prerequisite

(and sometimes a pitfall) for these sensors and probes. Sometimes, in situ probes can be
placed in external loops. The use of bypasses and additional peripheral equipment always
adds potential risks to the process and therefore need to be carefully considered.

Online Monitoring

sample is automatically withdrawn and analyzed.

The principal advantages of online methods are that sensor sterilization can be readily
accomplished, sample pretreatment (e.g. gassing, dilution, and removal of interferences) is
readily achievable, and sensor calibration can be built into the system.

The main disadvantages are a need for an effective and reliable sampling system and the
fact that the signal is discontinuous.

AGITATION MEASURING AND CONTROLLING DEVICE

Agitation speed can be measured by power consumed by agitator shaft. Wattmeter is

usually used in large scale process. It is a measure of power consumed for rotation of agitator
shaft. This measure is less accurate because power required to rotate against friction in the
bearing is taken into consideration.

Torsion dynamometer is used in small scale. This has to be placed outside the vessel and
less accurate due to friction.

Strain gauges can be mounted on shaft within fermenter from which electric signal is picked
up through lead wires passing out of fermenter via an axial hole.

Tachometer can be used to control the agitation speed. The rate of rotation is monitored
either by electromagnetic induction or voltage generation or light sensing or magnetic force.

Final choice is made by the type of signal required to record or monitor the signal. The
agitator
speed is also controlled by gear box usage, modifying the size of wheels and drive belts and
changing the drive motor.

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Speed Control System

The stirrer speed is controlled from the separate
module integrated into the stirrer unit. A set-point is
given and a tachometer in the motor provides a
feedback control signal. A power meter measures
the work done by the motor to ensure a constant
sitrring speed even under conditions of high
viscosity. An external set-point signal can be
supplied from the microprocessor unit, if required,
and speed adjustments can be linked to the level of
dissolved oxygen. A local display of actual value for
stirrer speed is provided on the control module.
A variable-frequency drive (VFD) (also termed adjustable-frequency drive, variable-speed
drive, AC drive, micro drive orinverter drive) is a type of adjustable-speed drive used

in electro-mechanical drive systems to control AC motor speed andtorque by varying motor

input frequency and voltage.