Bioreactor Design and Bioprocess Control

Overview

Summary of Lecture Content:

This module will probe the key underpinnings behind reactor design and the principles behind controlling a chemical process in the chosen reactor. Within this module, choosing the correct reactor for a given process will be discussed and the kinetic modelling applied to the reactor. Alongside this, a focus on bioreactors to facilitate the production of biopharmaceuticals on a large scale will be discussed along with some of the key parameters behind maximising product yield. Finally, control of the process will be discussed along with the methods of control and process automation. Within this module, there will be a marked design project which the students will complete individually, the motivation behind this type of work is that students will be able to take ownership of a piece of work and will require thought and originality of idea in terms of what they have been taught thus far in the course. Application of knowledge gathered and also literature sources will aid in the completion of this project. Following the completion of the design project, the students will then give a short presentation of their findings and ideas about the project.

Series 1: Reactor Design
This block will probe in detail the different types of reactor and which type would be applicable to which process. Determining how to relate the different types of reactor can be related to maximal heat and mass transfer will be discussed and proven using mathematical models. Moving on from the previous module, chemical equilibria and kinetics will be discussed in more details and these when applied to different types of reactor.
Series 1 Lectures:
• Lecture 1: Types of reactor
• Lecture 2: Appropriate choice of reactor
• Lecture 3: Linking reactor design to maximal heat and mass transfer
• Lecture 4: Chemical equilibria and kinetics

Series 2: Process Control
This block will examine the methods and motivation behind process control and list the hardware required for a process to be controlled automatically. Alongside this, issues arising during an automated process will be discussed and steps taken towards remedying issues will be discussed.
Series 2 Lectures:
• Lecture 5: Why a process needs to be controlled
• Lecture 6: Hardware required for a process to be controlled
• Lecture 7: Process dynamics
• Lecture 8: Root cause analysis of system malfunction

Series 3: Bioreactors
This block discusses the key elements of a bioreactor and what the typical reactor chosen for this purpose is, the critical process parameters required for the efficient operation of a bioreactor for the maximum yield of a biopharmaceutical product. Some discussion around what other types of reactors may be suitable for a specific type of biopharmaceutical and finally the mass balance for a biopharmaceutical production process.

Series 3 Lectures
• Lecture 9: Overview of a continuous stirred-tank reactor & components
• Lecture 10: Critical process parameters
• Lecture 11: Other potential reactors for a bioprocess
• Lecture 12: Mass balance

Series 4: Bioprocess Control
This block concerns the motivation for process control and also the methods employed for the full control of a process including the inputs & outputs, the sensors required for the control and also automation of a process.
Series 4 Lectures
• Lecture 13: Methods of control
• Lecture 14: Sensors
• Lecture 15: Process automation
• Lecture 16: Inputs & Outputs
Summary of workshops
• Workshop 1: This workshop will focus on the reactor choice for a specific need within an industrial setting and linking the chosen reactor to the principles of heat and mass transfer as covered in Chemical Engineering Principles this workshop will be performed in groups which will facilitate group discussion.
• Workshop 2: The aim of this workshop is to allow students to see and understand the main methods behind controlling a process and groupwork which will reinforce the lecture material
• Workshop 3: This workshop will focus on the typical reactor which would be employed for a biopharmaceutical production and also a key discussion on the critical process parameters. There will be some overlap between Workshop 2 and Workshop 3 whereby the critical process parameters and how they are controlled will be a major part of the groupwork
• Workshop 4: This workshop will focus on the inputs and outputs when controlling a bioprocess, the main aim of the workshop will be to design a process fully controlled and specifying the inputs and outputs of the system and which sensors are required for which operations within the system.

Summary of Module Delivery:
This block will be delivered in-person and also via recorded workshops which students can use in their own revision and study time to refer to. Due to the mathematical components of this module, there will be workshops made available for all students to attend in order to have an increased knowledge in the mathematical functions and models used in the determination of quantifiable values. These workshops will be led by an academic and supported by a PhD/ PDRA who can take part in break-out rooms and stimulate discussion between members of groups.

Learning Objectives

At the end of the module students will be able to:
• Recall the key aspects behind designing a reactor which is to be used for the production of a biopharmaceutical product
• Understand what it means and why it is necessary to control a process
• Describe the key features and components of a Continuous Stirred-Tank Reactor and why it is most commonly used for the plant-scale production of biopharmaceuticals
• Describe and explain the methods behind controlling a bioprocess including the required sensors and the inputs and outputs

Skills

Skills Associated with Module:
• Core skills in underlying physical sciences, in particular physics and chemistry as applied to solving problems
• Logical thinking
• STEM skills
• Communication and reporting writing skills

Assessment

Course Requirements:
Coursework submission: 100%
Total Coursework elements must be passed at: 50%