Figure 1. Integration of different process steps and external constraints that must be considered in the design of a new or improved process to produce a new or existing product. Consumables are materials or equipment parts that must be replaced from time to time (such as, filtration mermbranes, chromatographic resins, etc.). Energy consumed in the process by utilities is provided mainly by electricity, steam, and water.

Figure 2. Basic (ideal) reactor types and operational modes as well as the respective concentration profiles for a substrate S as a function of (residence) time (t). (a) STR, dc: stirred tank reactor, discontinuous; (b) STR, c: continuous; (c) STR, cas, c: cascade, continuous; (d) TR, c: tubular reactor, continuous (Q = volumetric flow; z = length. Indices: entry = 0; exit = E).

Figure 3. Graphical analysis of residence time required for a continuous stirred tank reactor and a tubular reactor, for different types of reactions. For explanation, see text.

Figure 4. Ratio of enzyme activities required for a continuous stirred tank reactor and a tubular reactor, for different initial substrate concentrations [S] ₀, given by simple Michaelis–Menten kinetics and a Michaelis constant (K _m) of 1 mM (Lilly, 1978).

Figure 5. Loop reactors (G = gas phase; L = liquid phase). (a) Simple principle with internal tube and stirrer; (b) slim type with baffles/breakers; (c) reactor with enlarged head (for three-phase systems and degassing); (d) bubble column loop reactor.

Figure 6. Reactor configurations with continuous stirred tank reactors. (a) Cascade of stirred tank reactors in the form of a tube subdivided into chambers. (b) Stirred tank reactor with subsequent ultrafiltration unit.

Figure 7. Reactor for penicillin hydrolysis, with differential fixed bed with immobilized penicillin amidase and a stirred tank reactor for neutralization of 6-aminopenicillanic acid formed. (1) Addition of penicillin, (2) addition of ammonia, (3) exit to extraction of 6-aminopenicillanic acid, (4) immobilized enzyme, (5) sieve plate, and (6) degassing.

Figure 8. Different configurations of tubular reactors. (a) Column with fixed bed of biocatalyst, (b) hollow fiber membrane reactor, (c) trickle bed reactor, (d) biofilter, and (e) fluidized bed reactor.

Figure 9. Industrial fluidized bed reactor for anaerobic wastewater treatment; working volume 500 m ³, height 30 m.(Reproduced from Jördening et al., 1996, with permission of Nordzucker AG, Braunschweig.)

Figure 10. Schematic illustration of deviations from ideal flow in stirred vessels (a) and tubular reactors (b–e). (a) Stagnant zones and short-circuit flow/channeling, (b) stagnant zones, (c) back mixing in local turbulent field, (d) insufficient axial mixing, and (e) channeling in fixed bed with catalyst.

Figure 11. (a) Residence time distribution E(t) for ideal continuous stirred tank (cSTR) and tubular (TR) and real reactors (rR); (b) Integral of the residence time distribution F(Θ) for ideal and real reactors.

Figure 12. (a) Residence time distribution in cascades of continuous stirred tank reactors; parameters: number of vessels. (b) Integral of the residence time distribution for cascades; N: number of vessels.

Figure 13. Residence time distribution with short circuit (simulated).

Figure 14. Flow patterns with circulation flow in stirred tank reactors. (a) Reactor with impeller in unsymmetrical position; (b) reactor with two impellers (H = height; d _R = reactor diameter; d _i = impeller diameter; (1–4) = circulation pathways) (Reuss and Bajpai, 1991).

Figure 15. Experimental and simulated signal from mixing after a tracer pulse.

Figure 16. Simulated dynamics of the tracer distribution at different times after a pulse onto the liquid surface in a stirred tank reactor (height/tank diameter ratio = 1.0, Rushton turbine, impeller/tank diameter ratio = 0.3125, impeller clearance/height of liquid = 0.31).(Reproduced from Schmalzried et al., 2003, with kind permission from Springer Science + Business Media.)

Figure 17. (a) Types of common impellers, in the sequence of application for media of different viscosity and the type of fluid flow; (i) = tangential to radial; (ii) axial fluid flow; (1) Rushton turbine; (2), (3) special types for high viscosity; (4) pitched blade turbine; (5) propeller; (6) MIG impeller (Ekato). (b) Correlations for estimating the mixing time for different types of impellers: s = with baffles; c = type 2; d = anchor; e = helical ribbon; f, fs = MIG impeller; gs = turbine; i = impeller; hs = propeller (Zlokarnik, 1972).

Figure 18. Process flow sheet of fluidized multiphase bed reactor. Product recovery from the zeolite suspension was performed by centrifugation, recycling of the substrate solution, desorption of isomaltose from the zeolite with ethanol, distillation and ethanol recycle(Reproduced with permission of Elsevier © 2004, from Berensmeier et al., 2004).

Figure 19. Scheme of integrated rhamnolipid production process management. BR: bioreactor; FC: fractionation column; FR: foam collection receptacle; MF: magnetic filter; P1 pump; V1/V2 valves (Heyd et al., 2010).

Figure 20. External configurations for ISPR with cooling crystallization. Cell retention is achieved by cell immobilization. The product solution is directly fed into the external crystallization loop to crystallize the product.The product-depleted mother liquor is recycled to the bioreactor (Buque-Taboada et al., 2006, reproduced with permission from Springer Science + Business Media).

Figure 21. Measurement and control units of a laboratory reactor for automated discontinuous penicillin hydrolysis. VM, VR: mechanically or electrically controlled valves; VE: storage tank; ZP; pump (Tischer, 1990).