Validation of computational fluid dynamics of shake flask experiments at moderate viscosity by liquid distributions and volumetric power inputs

Computational fluid dynamics (CFD) has recently become a pivotal tool in the design and scale-up of bioprocesses. While CFD has been extensively utilized for stirred tank reactors (STRs), there exists a relatively limited body of literature focusing on CFD applications for shake flasks, almost exclusively concentrated on fluids at waterlike viscosity. The importance of CFD model validation cannot be overstated. While techniques to elucidate the internal flow field are necessary for model validation in STRs, the liquid distribution, caused by the orbital shaking motion of shake flasks, can be exploited for model validation. An OpenFOAM CFD model for shake flasks has been established. Calculated liquid distributions were compared to suitable, previously published experimental data. Across a broad range of shaking conditions, at waterlike and moderate viscosity (16.7 mPa∙s), the CFD model's liquid distributions align excellently with the experimental data, in terms of overall shape and position of the liquid relative to the direction of the centrifugal force. Additionally, the CFD model was used to calculate the volumetric power input, based on the energy dissipation. Depending on the shaking conditions, the computed volumetric power inputs range from 0.1 to 7 kW/m3 and differed on average by 0.01 kW/m3 from measured literature data.

Past and current components-based detailing of particle image velocimetry: A comprehensive review

Particle image velocimetry has been widely used in various sectors from the automotive to aviation, research, and development, energy, medical, turbines, reactors, electronics, education, refrigeration for flow characterization and investigation. In this study, articles examined in open literature containing the particle image velocimetry techniques are reviewed in terms of components, lasers, cameras, lenses, tracers, computers, synchronizers, and seeders. The results of the evaluation are categorized and explained within the tables and figures. It is anticipated that this paper will be a starting point for researchers willing to study in this area and industrial companies willing to include PIV experimenting in their portfolios. In addition, the study shows in detail the advantages and disadvantages of past and current technologies, which technologies in existing PIV laboratories can be renewed, and which components are used in the PIV laboratories to be installed.

Analysis of hollow wall effect on the fluid dynamics in the orbitally shaken bioreactors

Orbitally shaking bioreactors (OSRs) have recently been increasingly applied in the biopharmaceutical industry because they can provide a suitable environment for mammalian cell growth and protein expression. Fluid dynamics information is crucial for analyzing or optimizing of different types of bioreactors. Considering that the structure has an important influence on the fluid dynamics in a bioreactor, it necessary to design or optimize its structure by the computational fluid dynamics (CFD) approach. The aim of this study is to optimize the wall structure of a hollow cylinder OSR proposed in our previous work. Based on previous research, the influences of the hollow wall of the OSR on fluid dynamics and the volumetric mass transfer coefficient ([Formula: see text]) were analysed by the established CFD model. The results showed that the mixing performance of OSR could be improved by decreasing the installation height of the hollow wall. An installation height of 30 mm was found to be most favourable for mixing. The reliability of the CFD model was verified by comparing the liquid wave height and liquid wave shape between the simulation and experiment. The shear stress in the hollow cylinder OSR was proven gentle for mammalian cell cultivation.

Characterization of hydrodynamics and volumetric power input in microtiter plates for the scale-up of downstream operations

Parameter estimation for scale-up of downstream operations from microtiter plates (MTPs) is mostly done empirically because engineering correlations between microplates and stirred tank reactors (STRs) are not yet available. It is challenging to change the operation mode from shaken MTPs to large-scale STRs. For the scale-up of STRs, volumetric power input is well-established although it is unclear whether this parameter can be used to transfer the operations from MTPs. We determine the volumetric power input in MTPs via the temperature increase caused by the motion of the liquid. The hydrodynamics in MTPs are studied with computational fluid dynamics (CFD). Mixing is investigated in 96-, 24-, and 6-well MTPs to cover different geometries, filling volumes, shaking diameters, and shaking frequencies. All CFD simulations are validated by experimental results, which now allows prediction of the volumetric power input and hydrodynamics at various conditions in MTPs without the need for further experiments. We provide a map of the power input achievable in MTPs. Based on this map, from knowing about large-scale conditions, adequate microscale conditions can be adjusted for process development. This enables the direct scale-up of downstream unit operations from MTPs to STRs.

Analysis of volumetric mass transfer coefficient (k L a) in small- (250 mL) to large-scale (2500 L) orbitally shaken bioreactors

In this study, the combination of dimensional analysis (DA) and analysis of variance (ANOVA) was used to predict the volumetric mass transfer coefficient (k _L a) values under different operating conditions for orbitally shaken bioreactors (OSRs) with different filling volumes. It was found that Reynolds number and the interaction between Froude number and geometric number have the largest impact on k _L a with impact indexes of 7.41 and 7.50, respectively. Moreover, the volume number has the largest negative impact on k _L a, with an impact index of - 5.34. Thus, an effective way to increase the oxygen supply is by increasing the shaking speed and shaking diameter or decreasing the vessel diameter. However, cell cultivation with a higher filling volume will have an increased risk of oxygen scarcity. Therefore, with the help of the k _L a prediction model, a suitable operating condition can be determined effectively and easily.

Mixing Performance Analysis of Orbitally Shaken Bioreactors

This study investigated the efficacy of a novel correlation of power input, energy dissipation rate and mixing time as a potential route to identify the orbitally shaken bioreactor (OSB) system. The Buckingham’s π-theorem was used to designate and transform dimensionless Newton numbers with five relevant power input variables. These variables were empirically varied to evaluate the correlation among the dimensionless numbers. The Newton number decreases with the increased shaking frequency and filling volume. Previous work has focused on optimizing the mixing process by evaluating different shaking and agitation mixing methods. We establish a new mixing process and assessable measurement of the mixing time in the OSB. An innovative explanation of mixing time for the thermal method is proposed. The optimal mixing time is independent of the temperature of filled liquid. The dimensionless mixing number remained constant in the turbulent regime and increasing with the increased liquid viscosity and filling volume. Our findings revealed that the observed correlation is a practical tool to figure the power consumption and mixing efficiency as cell cultivation in all OSB scales and is fully validated when scaling–up system.

Assessing behaviour of osteoblastic cells in dynamic culture conditions using titanium-doped phosphate glass microcarriers

Tissue engineering is a promising approach for bone regeneration; yet challenges remain that limit successful translation to patients. It is necessary to understand how real-world manufacturing processes will affect the constituent cells and biomaterials that are needed to create engineered bone. Bioactive phosphate glasses processed into microspheres are an attractive platform for expanding bone-forming cells and also for driving their osteogenic differentiation and maturation. The aim of this study was to assess whether Ti-doped phosphate glass microspheres could support osteoblastic cell responses in dynamic cell culture environments. Dynamic culture conditions were achieved using microwell studies under orbital agitation. Dimensionless parameters such as the Froude number were used to inform the choice of agitation speeds, and the impact on cell proliferation and microunit formation was quantified. We found that phosphate glass microspheres doped with titanium dioxide at both 5 and 7 mol% provided a suitable biomaterial platform for effective culture of MG63 osteoblastic cells and was not cytotoxic. Dynamic culture conditions supported expansion of MG63 cells and both 150 and 300 rpm orbital shake resulted in higher cell yield than static cultures at the end of the culture (day 13). The Froude number analysis provided insight into how the microunit size could be manipulated to enable an appropriate agitation speed to be used, while ensuring buoyancy of the microunits. These small-scale experiments and analyses provide understanding of the impact of fluid flow on cell expansion that will have increasing importance when scaling up to process technologies that can deliver clinical quantities of cell-microsphere units. Such knowledge will enable future engineering of living bone-like material using processing systems such as bioreactors that use mixing and agitation for nutrient transfer, therefore introducing cells to dynamic culture conditions.

Characterizing the fluid dynamics in the flow fields of cylindrical orbitally shaken bioreactors with different geometry sizes

Orbitally shaken bioreactors (OSRs) are commonly used for the cultivation of mammalian cells in suspension. To aid the geometry designing and optimizing of OSRs, we conducted a three-dimensional computational fluid dynamics (CFD) simulation to characterize the flow fields in a 10 L cylindrical OSR with different vessel diameters. The liquid wave shape captured by a camera experimentally validated the CFD models established for the cylindrical OSR. The geometry size effect on volumetric mass transfer coefficient (k_La) and hydromechanical stress was analyzed by varying the ratio of vessel diameter (d) to liquid height at static (h _L), d/h _L. The highest value of k_La about 30 h^-1 was observed in the cylindrical vessel with the d/h _L of 6.35. Moreover, the magnitudes of shear stress and energy dissipation rate in all the vessels tested were below their minimum values causing cells damage separately, which indicated that the hydromechanical-stress environment in OSRs is suitable for cells cultivation in suspension. Finally, the CFD results suggested that the d/h _L higher than 8.80 should not be adopted for the 10 L cylindrical OSR at the shaking speed of 180 rpm because the "out of phase" state probably will happen there.

Three-dimensional (3D) evaluation of liquid distribution in shake flask using an optical fluorescence technique

Background

Biotechnological development in shake flask necessitates vital engineering parameters e.g. volumetric power input, mixing time, gas liquid mass transfer coefficient, hydromechanical stress and effective shear rate. Determination and optimization of these parameters through experiments are labor-intensive and time-consuming. Computational Fluid Dynamics (CFD) provides the ability to predict and validate these parameters in bioprocess engineering. This work provides ample experimental data which are easily accessible for future validations to represent the hydrodynamics of the fluid flow in the shake flask.

Results

A non-invasive measuring technique using an optical fluorescence method was developed for shake flasks containing a fluorescent solution with a waterlike viscosity at varying filling volume (V_L = 15 to 40 mL) and shaking frequency (n = 150 to 450 rpm) at a constant shaking diameter (d_o = 25 mm). The method detected the leading edge (LB) and tail of the rotating bulk liquid (TB) relative to the direction of the centrifugal acceleration at varying circumferential heights from the base of the shake flask. The determined LB and TB points were translated into three-dimensional (3D) circumferential liquid distribution plots. The maximum liquid height (H_max) of the bulk liquid increased with increasing filling volume and shaking frequency of the shaking flask, as expected. The toroidal shapes of LB and TB are clearly asymmetrical and the measured TB differed by the elongation of the liquid particularly towards the torus part of the shake flask.

Conclusion

The 3D liquid distribution data collected at varying filling volume and shaking frequency, comprising of LB and TB values relative to the direction of the centrifugal acceleration are essential for validating future numerical solutions using CFD to predict vital engineering parameters in shake flask.

Electronic supplementary material

The online version of this article (doi:10.1186/s13036-017-0070-7) contains supplementary material, which is available to authorized users.

Towards modular bone tissue engineering using Ti–Co-doped phosphate glass microspheres: cytocompatibility and dynamic culture studies

The production of large quantities of functional vascularized bone tissue ex vivo still represent an unmet clinical challenge. Microcarriers offer a potential solution to scalable manufacture of bone tissue due to their high surface area-to-volume ratio and the capacity to be assembled using a modular approach. Microcarriers made of phosphate bioactive glass doped with titanium dioxide have been previously shown to enhance proliferation of osteoblast progenitors and maturation towards functional osteoblasts. Furthemore, doping with cobalt appears to mimic hypoxic conditions that have a key role in promoting angiogenesis. This characteristic could be exploited to meet the clinical requirement of producing vascularized units of bone tissue. In the current study, the human osteosarcoma cell line MG-63 was cultured on phosphate glass microspheres doped with 5% mol titanium dioxide and different concentrations of cobalt oxide (0%, 2% and 5% mol), under static and dynamic conditions (150 and 300 rpm on an orbital shaker). Cell proliferation and the formation of aggregates of cells and microspheres were observed over a period of two weeks in all glass compositions, thus confirming the biocompatibility of the substrate and the suitability of this system for the formation of compact micro-units of tissue. At the concentrations tested, cobalt was not found to be cytotoxic and did not alter cell metabolism. On the other hand, the dynamic environment played a key role, with moderate agitation having a positive effect on cell proliferation while higher agitation resulting in impaired cell growth. Finally, in static culture assays, the capacity of cobalt doping to induce vascular endothelial growth factor (VEGF) upregulation by osteoblastic cells was observed, but was not found to increase linearly with cobalt oxide content. In conclusion, Ti–Co phosphate glasses were found to support osteoblastic cell growth and aggregate formation that is a necessary precursor to tissue formation and the upregaulation of VEGF production can potentially support vascularization.