Alfa Laval Spiral Heat Exchanger

The design of continuous sterilization cycles may be approached in exactly the same way as for batch sterilization systems. The continuous system includes a time period during which the medium is heated to the sterilization temperature, a holding time at the desired temperature and a cooling period to restore the medium to the fermentation temperature. The temperature of the medium is elevated in a continuous heat exchanger and is then maintained in an insulated serpentine holding coil for the holding period. The length of the holding period is dictated by the length of the coil and the flow rate of the medium. The hot medium is then cooled to the fermentation temperature using two sequential heat exchangers — the first utilizing the incoming medium as the cooling source (thus conserving heat by heating-up the incoming medium) and the second using cooling water. The major advantage of the continuous process is that a much higher temperature may be utilized, thus reducing the holding time and reducing the degree of nutrient degradation. The required Del factor may be achieved by the combination of temperature and holding time which gives an acceptably small degree of nutrient decay. Richards (1968) quoted the following example to illustrate the range of temperature-time regimes which may be employed to achieve the same probability of obtaining sterility. The Del factor for the example sterilization was 45.7 and the following temperature time regimes were calculated to give the same Del factor:

Temperature Holding time

130° 2.44 minutes

135° 51.9 seconds

140° 18.9 seconds

150° 2.7 seconds

Furthermore, because a continuous process involves treating small increments of medium the heating-up and cooling-down periods are very small compared with those in a batch system. There are two types of continuous sterilizer which may be used for the treatment of fermentation media: the indirect heat exchanger and the direct heat exchanger (steam injector).

The most suitable indirect heat exchangers are of the double-spiral type which consists of two sheets of high-grade stainless steel which have been curved around a central axis to form a double spiral, as shown in Fig. 5.8. The ends of the spiral are sealed by covers. A full scale example is shown in Fig. 5.9. To achieve sterilization temperatures steam is passed through one spiral and medium through the other in countercurrent o

Alfa Laval Spiral Heat Exchanger
Fig. 5.8. A schematic representation of a spiral heat exchanger (Alfa-Laval Engineering Ltd, Brentford, Middlesex).

streams. Spiral heat exchangers are also used to cool the medium after passing through the holding coil. Incoming unsterile medium is used as the cooling agent in the first cooler so that the incoming medium is partially heated before it reaches the sterilizer and, thus, heat is conserved.

The major advantages of the spiral heat exchanger are:

(i) The two streams of medium and cooling liquid, or medium and steam, are separated by a continuous stainless steel barrier with gasket seals being confined to the joints with the end plates. This makes cross contamination between the two streams unlikely.

(ii) The spiral route traversed by the medium allows sufficient clearances to be incorporated for the system to cope with suspended solids. The exchanger tends to be self-cleaning which reduces the risk of sedimentation, fouling and 'burning-on'.

Indirect plate heat exchangers consist of alternating plates through which the countercurrent streams are circulated. The plates are separated by gaskets and failure of these gaskets can cause cross-contamination between the two streams. Also, the clearances between the plates are such that suspended solids in the medium may block the exchanger and, thus, the system is only useful in sterilizing completely soluble media. However, the plate exchanger is more adaptable than the spiral system in that extra plates may be added to increase its capacity.

The continuous steam injector injects steam directly into the unsterile broth. The advantages and disadvan tages of the system have been summarized by Banks (1979):

(i) Very short (almost instantaneous) heating up times.

(ii) It may be used for media containing suspended solids.

(iii) Low capital cost.

(iv) Easy cleaning and maintenance.

(v) High steam utilization efficiency.

However, the disadvantages are:

(i) Foaming may occur during heating.

(ii) Direct contact of the medium with steam requires that allowance be made for condense dilution and requires 'clean' steam, free from anticorrosion additives.

In some cases the injection system is combined with flash cooling, where the sterilized medium is cooled by passing it through an expansion valve into a vacuum chamber. Cooling then occurs virtually instantly. A flow chart of a continuous sterilization system using direct steam injection is shown in Fig. 5.10. In some cases a combination of direct and indirect heat exchangers may be used (Svensson, 1988). This is especially true for starch-containing broths when steam injection is used for the pre-heating step. By raising the temperature virtually instantaneously the critical gelatinization temperature of the starch is passed through very quickly and the increase in viscosity normally associated with heated starch colloids can be reduced.

The most widely used continuous sterilization system is that based on the spiral heat exchangers and a typical layout is shown in Fig. 5.11. The plant is sterilized prior to sterilization of the medium by circulating hot water through the plant in a closed circuit. At the same time, the fermenter and the pipework between the fermenter and the sterilizer are steam sterilized. Heat conservation is achieved by cooling the sterile medium against cold, incoming unsterile medium which will then be partially heated before it reaches the sterilizer.

The Del factor to be achieved in a continuous sterilization process has to be increased with an increase in scale, and this is calculated exactly as described in the consideration of the scale up of batch regimes. Thus, if the volume to be sterilized is increased from 1000 dm3 to 10,000 dm3 and the risk of failure is to remain at 1 in 1000 then the Del factor must be increased from 34.5 to 36.8. However, the advantage of the continuous

Industrial Heat Exchanger Diagram
Fig. 5.9. Industrial scale spiral heat exchanger (Alfa-Laval Engineering Ltd., Brentford, Middlesex).
Industrial Scale Spiral Heat Exchanger
Water, detergent
System Engineering Process Spiral

Sterilized product to fermenter

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