Introduction
The compact 5 L Fermentation reactor is a versatile system ideal for bench and pilot experiments. With integrated temperature control, agitation, precise dosing, multi-probe sensing, and data handling capabilities, it offers a comprehensive platform for safe and stable operation while recording key parameters for reproducible results.
Fermentation reactor components
Modular design
The hardware is divided into several modules, including a water-bath temperature unit, an acid-base dosing unit, a reactor unit, a sensor unit, a lifting unit, a mobile stand, and a control box. The HMI located within the control box oversees and manages these operations, with the exception of the manual lifting and movement. The power supply required is AC 220 V with a ±10% tolerance and allowed fluctuation of 2.5%, using a three-wire connection.
Water-bath temperature unit
The unit is equipped with a field box containing a circulating pump, heater, heat exchanger, cooling-water solenoid, and water-bath temperature probe. Insulated piping connects to a jacketed reactor and a top temperature sensor. The software reads signals from the sensors and controls the heater and cooling-water solenoid for precise automatic temperature control. Properly connecting the cooling water and maintaining it at 20-30 °C ensures effective cooling in the jacket loop.
Agitation system
A servo drive is responsible for powering an explosion-proof motor, which in turn, uses a 1:30 gearbox to drive the impeller. The motor has a speed range of 0–3000 rpm, but once the reduction takes place, the impeller runs at a speed of 0–100 rpm.
Peristaltic dosing
The precision controller operates a peristaltic head for small-quantity dispensing and precise pH modifications.
Sensor suite
The system utilizes temperature, pH, and DO sensors for vessel measurements. Prior to initial use, the pH electrode sheath must be removed, and the electrode should be placed in a buffer for calibration and verification of functionality. Agitation should never begin with the sheath still on, as this could result in damage to the electrode by breaking it with the impeller.
Lifting unit & mobile stand
The setup process is aided by manual lifting. Before powering on, the pH electrode sheath should be removed using the lift. It is also important to examine the internal screws for any movement during transport and securely close the head and body. Always ensure that the two lid screws are checked before attempting to lift. In order to relocate the system, disconnect all power, water, and feed lines when using the mobile stand. If the floor is not even, use tools instead of pushing to move the system.
Control-box boundary
The control box regulates temperature, stirring, dosing, and sensing, but it does not have any influence on lifting or movement.
Application Fields
Resource Recovery from Organic Waste
This is currently the most economically viable application direction. Biological fermentation reactors can process diverse organic wastes, transforming them into valuable resources:
- Agricultural residues: Such as crop straw and livestock manure.
- Food industry wastewater: Including high-concentration organic effluents from brewing, sugar refining, dairy processing, and starch manufacturing.
- Municipal organic waste: Covering food scraps, sludge, and similar materials.
- During this process, the reactor not only produces fermentation but also simultaneously degrades pollutants, reducing wastewater/waste treatment costs.
Chemical and Refining Industries
The produced biohydrogen can be used locally or after purification in chemical processes, such as serving as a hydrogen source for hydrogenation reactions or for synthesizing ammonia, methanol, etc. This helps reduce the reliance of these high-hydrogen-consumption industries on fossil fuel-derived hydrogen (gray hydrogen).
Aerospace and Specialized Applications
Hydrogen has a long history as a fuel in aerospace due to its high energy density and clean combustion products. Developing biohydrogenation technologies offers a promising solution for future space stations or extraterrestrial bases. This approach enables in-situ production of energy and oxygen (via the reverse reaction in hydrogen-oxygen fuel cells) using local resources such as astronaut metabolic waste and plant residues.
Scientific Research and Education
Biological hydrogen production reactors serve as vital research tools in microbiology, bioengineering, energy science, and environmental science. They facilitate investigations into the metabolic mechanisms of hydrogen-producing microorganisms, optimization of process parameters, and development of novel reactor configurations. Simultaneously, they function as demonstration equipment for teaching related disciplines in higher education institutions.
Pre-Run Checks & Safety Notes
- Ensure proper connection and maintain a temperature of 20–30 °C for the cooling water. This is essential for the jacket loop to be effectively cooled by the system.
- Before first use, be sure to remove the sheath and calibrate the pH electrode in buffer solution. Remember to start stirring after removing the sheath to prevent any potential damage to the electrode.
- To remove the sheath, manually lift and inspect the internal fasteners. Once done, close both the lid and body. Prior to lifting, ensure that the two lid screws are secure.
- To maintain smooth operations, ensure all power, water, and feed lines are disconnected before relocating the unit. When moving across uneven surfaces, handle with appropriate tools rather than pushing.
Selection & Configuration Highlights
- Volume: 5 L.
- Agitation: motor 0–3000 rpm; with 1:30 reduction, impeller 0–100 rpm.
- Feeding: peristaltic system for small-dose addition and micro pH control.
- Power: AC 220 V, ±10%, 2.5% fluctuation, three-wire.
- Structure: jacket + insulation, heating/cooling, top mechanical stirring, PLC/HMI.
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