Unit 1 Introduction

10 lecture hours

• From traditional bioprocess design to systems biology approaches
• Fundamentals of reaction types and reaction order
• The effect of temperature on reaction rates (Arrhenius equation and activation energy concepts)
• Microbial growth kinetics: Monod model
• substrate inhibition, and maintenance energy concepts
• Batch reactor data interpretation for reversible and irreversible reactions
• constant volume batch reactor modeling
• application of integral and differential methods of kinetic data analysis
• Introduction to structured and unstructured models for microbial growth

Unit 2 Bioreactor Systems

15 lecture hours

• Definitions and fundamental differences between chemical reactors and bioreactors
• Classification of bioreactors: stirred-tank
• packed- bed, fluidized-bed
• bubble column
• membrane bioreactors
• Reactor configurations and operation modes: batch
• Description of a conventional bioreactor: vessel components
• aeration systems
• instrumentation and control systems
• sensors (pH, DO, temperature)
• Design and construction criteria of bioreactors: material selection (hygiene
• aseptic operations
• sterilization (SIP/CIP systems)
• Residence time distribution (RTD) analysis
• concentration profiles
• temperature distribution in bioreactors
• Models of non-ideal reactors: dispersion model
• tanks- in-series model, and compartmental modelling
• Introduction to Computational Fluid Dynamics (CFD) for simulating bioreactor performance

Unit 3 Design of Bioreactors

10 lecture hours

• Design considerations for isotropic and non-isotropic systems
• Design equations for enzyme reactors (immobilized and free enzymes)
• Kinetic modelling for batch microbial growth
• Design of plug flow reactors (PFR) and continuous stirred-tank reactors (CSTR)
• including concepts of washout and dilution rate
• Biomass recycle and retention strategies: membrane bioreactors
• cell recycle systems
• Design and analysis of multiple CSTRs in series (with and without biomass recycle)
• Estimation of kinetic and stoichiometric parameters through laboratory and pilot studies
• Role of mixing
• shear stress, and oxygen transfer in industrial bioprocesses
• introduction to scale-up criteria (constant tip speed
• constant volumetric power input
• constant kLa)
• Advanced mixing strategies for high-viscosity fermentation and non- Newtonian fluids

Unit 4 Bioprocess Plant Design

• General considerations for bioprocess plant layout and equipment sizing
• Mass and energy balance development for bioprocesses
• Process flow diagram (PFD) 10 Program Name: Bachelor of Engineering Level: UG Branch: Biotechnology Subject Code: BE04004021 Subject Name: Bio-Reaction Engineering and piping & instrumentation diagrams (P&ID) creation
• Materials of construction: selection for biocompatibility
• durability, and regulatory compliance (GMP standards)
• Design and specification of heat transfer (e.g.
• heat exchangers) and mass transfer equipment (e.g.
• gas spargers
• distillation columns) for bioprocesses
• Utility systems: steam generation
• clean-in-place (CIP)
• sterilize-in- place (SIP)
• compressed air, and water purification systems
• Introduction to process control systems: SCADA
• distributed control systems (DCS), and bioreactor automation
• Bioprocess economics: cost estimation
• return on investment (ROI)
• life-cycle assessment (LCA)
• Risk analysis and safety considerations: biosafety levels (BSL)
• containment strategies
• HAZOP analysis
• Introduction to regulatory aspects: Good Manufacturing Practices (GMP)
• validation and qualification of bioprocess plants
• regulatory guidelines from FDA, EMA