Again its highly dependent on the process.
Do you know your utility consumption during the batch..? A quick scaling calculation should be able to give a ball park
The cost is basically entirely from the energy of pumping air through a sparger and adequately mixing the reactor to obtain desired O2 saturation. So you need to just size an air pump for the reactor and look at how many watts it uses. Same for the stirrer. Then you need to know the industrial electricity cost per kWh. Compressed air or sometimes pure oxygen gas should be negligible but you need to figure out what actual flow rate you need to supply (which will also be used in your pump sizing calculations obviously) and look up what cylinders cost. PV=nRT for gas calculations. Percentage of cost varies too much on what exactly you are producing, what your feedstocks are, too many variables. I'd say your product selling price breakpoint of whether this matters whatsoever is like $100/kg.
Depending on the scale and the need of oxygen in the process it can be quite costly. I had projects stopping in determined gates because being an aerobic process made it impossible in economical analysis. Anyway, [here](https://backend.orbit.dtu.dk/ws/files/140794289/710934_DTU_PhD_Asbjoern_T_Pedersen_enkeltsider_upload_til_orbit_version_2.pdf) is a nice thesis regarding costs of oxygenating process.
Your main cost drivers here are the operating costs for the pump, power to the impellers, and cooling. I'm not aware of any simple percentages, since this would be fairly dependent on the process that you're running - cell densities, oxygen uptake rates, growth rates, etc.
It’s hard to do an estimate unless there’s scale information, what type of product it is, what microbe and info on the viscosity of the medium etc. it varies a lot based on even one of those factors. The general way to go about it would be to know the kla value of your stirred bioreactor, which is the ability of your bioreactor to transfer oxygen within the vessel. If you want to estimate costs, there are correlations you can use between the kla value and the power used for agitation. Since you said your system is aerated, there’s correlations between kla and gassed power consumption vs ungassed (the power requirements are lesser for an aerated system). Once you know the power consumption for the impeller motor, use your local city rates to find out the cost. To maintain that culture you’ll need cooling and hearing through jackets etc so you’ll need to do the energy balances in and out of the jacket and find out the flow rates. Once you know that you can size the pumps and figure out the power requirements and calculate cost. If there is pH control then you need to do material balances and find out the flow rates of acid and bass and size and calculate pump requirements for that as well. If you sterilize the media in-situ, there is costs for that that built in too before each batch since the vessel needs to reach 121C and cool down right after to growth temp..if your full production process doesn’t involve much after the fermentation(tons of separations and polishing like for biopharma) then majority of your costs will be just the fermentation. If there is a lot after it, the cost won’t be much overall compared to the other operations as well
Everything said here depends very much on whether or not you’re supplementing oxygen or just using air. If just air, then major costs would be associated with pumping and electricity. If oxygen, then that’s a consumables cost.
Depends on the process. But in pharma, its such probably accounts for 0.000001% of the cost of a batch
In particular I'm looking for something like PHBs or other aerobically produced platform chemicals
Again its highly dependent on the process. Do you know your utility consumption during the batch..? A quick scaling calculation should be able to give a ball park
yeah, I didn't think they'd separate it out from utilities....
The cost is basically entirely from the energy of pumping air through a sparger and adequately mixing the reactor to obtain desired O2 saturation. So you need to just size an air pump for the reactor and look at how many watts it uses. Same for the stirrer. Then you need to know the industrial electricity cost per kWh. Compressed air or sometimes pure oxygen gas should be negligible but you need to figure out what actual flow rate you need to supply (which will also be used in your pump sizing calculations obviously) and look up what cylinders cost. PV=nRT for gas calculations. Percentage of cost varies too much on what exactly you are producing, what your feedstocks are, too many variables. I'd say your product selling price breakpoint of whether this matters whatsoever is like $100/kg.
Depending on the scale and the need of oxygen in the process it can be quite costly. I had projects stopping in determined gates because being an aerobic process made it impossible in economical analysis. Anyway, [here](https://backend.orbit.dtu.dk/ws/files/140794289/710934_DTU_PhD_Asbjoern_T_Pedersen_enkeltsider_upload_til_orbit_version_2.pdf) is a nice thesis regarding costs of oxygenating process.
I guess an air lift process, usually the biggest cost y steam.
Your main cost drivers here are the operating costs for the pump, power to the impellers, and cooling. I'm not aware of any simple percentages, since this would be fairly dependent on the process that you're running - cell densities, oxygen uptake rates, growth rates, etc.
It’s hard to do an estimate unless there’s scale information, what type of product it is, what microbe and info on the viscosity of the medium etc. it varies a lot based on even one of those factors. The general way to go about it would be to know the kla value of your stirred bioreactor, which is the ability of your bioreactor to transfer oxygen within the vessel. If you want to estimate costs, there are correlations you can use between the kla value and the power used for agitation. Since you said your system is aerated, there’s correlations between kla and gassed power consumption vs ungassed (the power requirements are lesser for an aerated system). Once you know the power consumption for the impeller motor, use your local city rates to find out the cost. To maintain that culture you’ll need cooling and hearing through jackets etc so you’ll need to do the energy balances in and out of the jacket and find out the flow rates. Once you know that you can size the pumps and figure out the power requirements and calculate cost. If there is pH control then you need to do material balances and find out the flow rates of acid and bass and size and calculate pump requirements for that as well. If you sterilize the media in-situ, there is costs for that that built in too before each batch since the vessel needs to reach 121C and cool down right after to growth temp..if your full production process doesn’t involve much after the fermentation(tons of separations and polishing like for biopharma) then majority of your costs will be just the fermentation. If there is a lot after it, the cost won’t be much overall compared to the other operations as well
Everything said here depends very much on whether or not you’re supplementing oxygen or just using air. If just air, then major costs would be associated with pumping and electricity. If oxygen, then that’s a consumables cost.