Balanço material de uma planta industrial produtora de esporos de Metarhizium anisopliae por cultivo em estado sólido em biorreator de leito empacotado
Carregando...
Data
2021-06-01
Autores
Título da Revista
ISSN da Revista
Título de Volume
Editor
Universidade Estadual Paulista (Unesp)
Resumo
O aumento expressivo previsto na necessidade produtiva dos esporos de Metarhizium anisopliae, apesar da sua produção ser ainda semi-artesanal, desperta o interesse pelo uso de biorreatores de cultivo em estado sólido como uma alternativa promissora para o aprimoramento tecnológico do processo. Pressupondo que questões técnicas e operacionais para ampliação de escala estejam resolvidas, este trabalho teve por objetivo estruturar e dimensionar, em termos de balanço material, o processo de produção industrial dos esporos do fungo M. anisopliae otimizados pelo emprego de equipamentos com destaque ao biorreator de leito empacotado para o cultivo em estado sólido. O processo de produção proposto é constante e comporta algumas etapas contínuas e em bateladas, de modo que o fluxograma de processo e a cronologia das etapas buscaram solucionar esta dificuldade. Os cálculos deste projeto baseiam-se na produção de esporos de duas biofábricas localizadas no interior de São Paulo, fundamentando-se na área, em hectares, de cana de açúcar beneficiada, no Brasil, pela aplicação dos esporos de M. anisopliae para combate da cigarrinha da cana-de-açúcar. Desta forma, adotou-se uma empresa de pequeno porte com capacidade produtiva de 6.1017 esporos/ano e outra de grande porte com capacidade produtiva 10 vezes superior. Os principais gargalos operacionais foram identificados e soluções apontadas e, a partir dos cálculos de fluxo de massa, a quantidade e capacidade nominal dos equipamentos propostos foram estabelecidas, detalhando-se estes equipamentos sempre que possível. Definiu-se a forma de esterilização dos substratos, através da operação contínua com a injeção de vapor saturado, e posterior resfriamento, ocorrendo em um tambor rotativo. Estabeleceu-se o cultivo submerso para a produção de inóculo em biorreatores agitados. A mistura e inoculação da biomassa foram configuradas para ocorrer continuamente em tambor rotativo. O cultivo em estado sólido para a produção dos esporos foi proposto em biorreatores de leito empacotado, instalando-se helicoide perfurado em seu interior para auxiliar no carregamento, descarregamento e estruturação da biomassa durante o cultivo, além de prover ar ao sistema. A extração dos esporos foi proposta em tambor rotativo acoplado a dois ciclones para captação dos esporos e a secagem, em outro conjunto de ciclones. Por fim, a formulação oleosa desenvolvida foi obtida em misturador. Para a empresa de pequeno porte são necessários 12 biorreatores de leito empacotado de 4 m3 , enquanto para a empresa de grande porte utilizam-se 36 biorreatores de 13,33 m3. O impacto do reuso do arroz foi avaliado observando-se com um único reuso uma redução de 44,3% de arroz a ser adquirido anualmente. A viabilidade econômica para emprego das modificações foi avaliada, tomando como parâmetro o Capital expenditure, onde as etapas de downstream correspondem a 58% dos custos diretos.
The significant increase foreseen in the productive need of Metarhizium anisopliae spores, despite its semi-artisanal production, arouses interest in the use of solid state culture bioreactors as a promising alternative for the technological improvement of the process. Assuming that technical and operational issues for scaling up are resolved, this work aimed to structure and dimension, in terms of material balance, the industrial production process of spores of the fungus M. anisopliae. Optimized by the use of equipment, especially the packed-bed bioreactor for solid state cultivation. The proposed production process is constant and includes some continuous steps and batch. So the process flowchart and the chronology of the steps sought to solve this difficulty. The calculations for this project are based on the production of spores from two biofactories located in the interior of São Paulo, based on the area, in hectares, of sugarcane processed in Brazil by the application of M. anisopliae spores to combat the Sugarcane leafhopper. Thus, a small company with a production capacity of 6.1017 spores/year and a large company with a production capacity 10 times higher was adopted. The main operational bottlenecks were solutions identified and, from the mass flow calculations, the quantity and nominal capacity of the proposed equipment were established, detailing this equipment whenever possible. The form of sterilization of the substrates was defined, through continuous operation with the injection of saturated steam, and subsequent cooling, taking place in a rotating drum. Submerged cultivation for inoculum production in stirred bioreactors was established. The mixing and inoculation of the biomass was configured to take place continuously in a rotating drum. Solid state cultivation for the production of spores was proposed in packed-bed bioreactors, installing a perforated helicoid inside to assist in loading, unloading and structuring of biomass during cultivation, in addition to providing air to the system. The extraction of spores was proposed in a rotating drum coupled to two cyclones for capturing the spores and drying, in another set of cyclones. Finally, the oily formulation developed was obtained in a mixer. For the small company, 12 packed bed bioreactors of 4 m3 are needed, while for the large company 36 bioreactors of 13.33 m3 are used. The impact of rice reuse was evaluated by observing a 44.3% reduction of rice to be purchased annually with a single reuse. The economic feasibility of using the modifications was evaluated, taking as a parameter the Capital Expenditure, where the downstream steps correspond to 58% of direct costs.
The significant increase foreseen in the productive need of Metarhizium anisopliae spores, despite its semi-artisanal production, arouses interest in the use of solid state culture bioreactors as a promising alternative for the technological improvement of the process. Assuming that technical and operational issues for scaling up are resolved, this work aimed to structure and dimension, in terms of material balance, the industrial production process of spores of the fungus M. anisopliae. Optimized by the use of equipment, especially the packed-bed bioreactor for solid state cultivation. The proposed production process is constant and includes some continuous steps and batch. So the process flowchart and the chronology of the steps sought to solve this difficulty. The calculations for this project are based on the production of spores from two biofactories located in the interior of São Paulo, based on the area, in hectares, of sugarcane processed in Brazil by the application of M. anisopliae spores to combat the Sugarcane leafhopper. Thus, a small company with a production capacity of 6.1017 spores/year and a large company with a production capacity 10 times higher was adopted. The main operational bottlenecks were solutions identified and, from the mass flow calculations, the quantity and nominal capacity of the proposed equipment were established, detailing this equipment whenever possible. The form of sterilization of the substrates was defined, through continuous operation with the injection of saturated steam, and subsequent cooling, taking place in a rotating drum. Submerged cultivation for inoculum production in stirred bioreactors was established. The mixing and inoculation of the biomass was configured to take place continuously in a rotating drum. Solid state cultivation for the production of spores was proposed in packed-bed bioreactors, installing a perforated helicoid inside to assist in loading, unloading and structuring of biomass during cultivation, in addition to providing air to the system. The extraction of spores was proposed in a rotating drum coupled to two cyclones for capturing the spores and drying, in another set of cyclones. Finally, the oily formulation developed was obtained in a mixer. For the small company, 12 packed bed bioreactors of 4 m3 are needed, while for the large company 36 bioreactors of 13.33 m3 are used. The impact of rice reuse was evaluated by observing a 44.3% reduction of rice to be purchased annually with a single reuse. The economic feasibility of using the modifications was evaluated, taking as a parameter the Capital Expenditure, where the downstream steps correspond to 58% of direct costs.
Descrição
Palavras-chave
Metarhizium anisopliae, Biorreator, Fluxograma de processo, Produção industrial, Balanço material, Viabilidade econômica, Bioreactor, Process flowchart, Industrial production, Material balance, Economic viability