Bioreactor Design and Bioprocess Control

Overview

Summary of Lecture Content:

This module will focus on reactor design and the principles behind controlling a bio-process in the chosen reactor. Reaction rate, mass balance and kinetics will be covered and discussed in detail. Within this module, choosing the correct reactor for a given process will be discussed. There will be consideration of the role of bioreactors in facilitating the production of biopharmaceuticals along with some of the key parameters required for maximising product yield. Finally, control of the process and the critical parameters will be discussed along with the methods of control.

Within this module, there will be
1. a marked design project which the students will complete in a group,
2. a marked set of questions which the students will complete individually.

The students will be able to take ownership of a piece of work and will need to apply thought and originality of idea in terms of what they have been taught thus far in the course. Application of learning content and also literature sources will aid in the completion of assessments.

Series 1: Chemical Reactor Design

This block explores different types of chemical reactor and which type would be applicable to which process. In determining how to relate the different types of reactor, chemical equilibria and kinetics will be discussed and applied. Reaction rates will be discussed and proven using mathematical models. Multiple reactions in continuous reactors are also covered. Finally, the practicalities of catalytic reactors and related mass transfer will be discussed to build the foundations for the move to more specific bioreactors.

Series 1 Lectures:
* Lecture 1: Introduction to chemical reactors;
* Lecture 2-3: Types of reactors, reaction rate in batch reactors;
* Lecture 4-5: Single Reaction in continuous isothermal reactors, and reactor design and connections;
* Lecture 6-7: Multiple Reactions in continuous reactors;
* Lecture 8: Catalytic Reactors and mass transfer

Series 2: Bioreactor Design and Process Control

This block discusses the key elements of a bioreactor and which reactors should be chosen for various purposes. The critical process parameters required for the efficient operation of a bioreactor for the maximum yield of a biopharmaceutical product will be discussed. This block will also examine the methods and motivation behind process control and list the hardware required for a process to be controlled automatically.

Series 2 Lectures
* Lecture 9-10: Introduction to bioreactors; continuous stirred-tank reactor & components, and other bioreactors;
* Lecture 11-12: Design challenges and process control methods, critical process parameters for bioreactor design
* Lecture 13-15: Bioreactor Design and Bio-Process Control: Case studies
* Lecture 16-18: Guest lectures: Biopharmaceutical Industry Front

Summary of workshops
* Workshop 1: This workshop will focus on the practices on the reaction mass balance, kinetics, reaction rate and equilibrium. This workshop will focus on the reactor choice for a specific need within an industrial setting and linking the chosen reactor as covered in Chemical Engineering Principles. This workshop will be performed in groups which will facilitate group discussion.
* Workshop 2: This workshop will focus on the most commonly used bioreactor which is employed for a biopharmaceutical production. Key topics concern critical process parameters and the inputs and outputs when controlling a bioprocess. This workshop will be performed in groups which will facilitate group discussion. The main aim of the workshop will be to design a bioreactor whereby the critical process parameters are controlled.

Summary of Module Delivery:
Due to the mathematical components of this module, the workshops will cover relevant practice questions in order to increase knowledge of and capability in use of the mathematical functions and models used in the determination of quantifiable values. These workshops will be led by an academic and stimulate discussion between members of groups. Online Seminars are also arranged to facilitate the students’ study following the workshops.

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 is fundamentally meant by controlling a process, its variables and why it is necessary.
• 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

Skills

Skills Associated with Module:

* Core skills in underlying physical sciences, in particular chemistry and mathematics as applied to solving problems
* Logical thinking
* STEM skills
* Communication and reporting presenting skills

Assessment

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

Assessment Profile
Element type Element weight (%)
1. Workshop problems 40
2. Design project + Presentation 60