Basic function: material transformation
The core objective of both reactors and fermenters is the conversion of substances:
- Reactor: Conversion of raw materials into target products (e.g. ammonia, plastics) through chemical reactions or physical processes (e.g. catalysis, polymerisation).
- Fermenter: conversion of substrates into bioproducts (e.g. alcohol, antibiotics) through the metabolic activity of microorganisms or cells.
Similarity in nature: both rely on energy input (e.g. heat, mechanical agitation) and process control to optimise conversion efficiency.
Similarity of equipment structure
Basic components: all are closed vessels equipped with the following common components:
- Stirring system: for mixing the reactants or culture fluids (mechanical stirring paddles, gas bubbles, etc.).
- Heat transfer system: jacket or coil for temperature control (e.g. cooling water circulation, steam heating).
- Sensors and control systems: to monitor and regulate parameters such as temperature, pressure, pH, dissolved oxygen, etc.
- Inlet and outlet: for adding raw materials or discharging products.
Commonality of process control
Key parameters monitoring
- Temperature: all need to be precisely controlled (e.g. high temperature for chemical reactions, constant temperature for fermentation).
- Mixing efficiency: relies on stirring or gas distribution to ensure homogeneity.
- Mass and heat transfer: optimising reaction rates or microbial metabolic efficiency.
Automation and data logging
- Modern reactors and fermenters are often equipped with PLC or computer systems for real-time monitoring and feedback.
Crossover of application areas
Dual properties of bioreactors
- Bioreactors are both a type of reactor and can be considered as an extension of fermenters (e.g. for mammalian cell culture).
- For example, in vaccine production, both the precision control of a reactor and the aseptic environment of a fermenter are required.
Product types may overlap
- Certain bio-based chemicals (e.g. lactic acid, ethanol) can be produced both in conventional fermenters and synthesised in enzyme-catalysed reactors.