CFD simulations and experimental validation of homogenisation curves and mixing time in stirred Newtonian and pseudoplastic liquids

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.

An analysis of organism lifelines in an industrial bioreactor using Lattice-Boltzmann CFD

Euler-Lagrange CFD simulations, where the biotic phase is represented by computational particles (parcels), provide information on environmental gradients inside bioreactors from the microbial perspective. Such information is highly relevant for reactor scale-down and process optimization. One of the major challenges is the computational intensity of CFD simulations, especially when resolution of dynamics in the flowfield is required. Lattice-Boltzmann large-eddy simulations (LB-LES) form a very promising approach for simulating accurate, dynamic flowfields in stirred reactors, at strongly reduced computation times compared to finite volume approaches. In this work, the performance of LB-LES in resolving substrate gradients in large-scale bioreactors is explored, combined with the inclusion of a Lagrangian biotic phase to provide the microbial perspective. In addition, the hydrodynamic performance of the simulations is confirmed by verification of hydrodynamic characteristics (radial velocity, turbulent kinetic energy, energy dissipation) in the impeller discharge stream of a 29 cm diameter stirred tank. The results are compared with prior finite volume simulation results, both in terms of hydrodynamic and biokinetic observations, and time requirements.

Simulation and Experimental Investigation of the Radial Groove Effect on Slurry Flow in Oxide Chemical Mechanical Polishing

Slurry flow on the pad surface and its effects on oxide chemical mechanical polishing (CMP) performance were investigated in simulations and experiments. A concentric groove pad and the same pad with radial grooves were used to quantitatively compare the slurry saturation time (SST), material removal rate (MRR), and non-uniformity (NU) in polishing. The monitored coefficient of friction (COF) and its slope were analyzed and used to determine SSTs of 25.52 s for the concentric groove pad and 16.06 s for a certain radial groove pad. These values were well correlated with the simulation prediction, with around 5% error. Both the laminar flow and turbulent flow were included in the sliding mesh model. The back mixing effect, which delays fresh slurry supply, was found in the pressure distribution of the wafer–pad interface.

Evaluation of the mixing quality of high-viscosity yield stress fluids in a tubular reactor

In this study, the mixing quality of high-viscosity yield stress fluid (Carbopol aqueous solution) under laminar and turbulent flow regimes was evaluated through a numerical experimental study. A three-dimensional computational fluid dynamics large-eddy simulation (CFD-LES) model was employed to capture large-scale vortex structures. The proposed CFD model was validated by the experimental data in terms of mean velocity profiles and velocity-time history. Thereafter, the CFD model was applied to simulate the residence time distribution using the tracking technique: tracer pulse method and step method. In addition, the non-ideal flow phenomena caused by molecular diffusion and eddy diffusion were evaluated. The effects of the rheological properties on the mixing performance were also investigated. The presented results can provide useful guidance to enhance mass transfer in reactors with high-viscosity fluids.

The impact of clearance on mixing time for interface-added substrate

This study was carried out to find the optimum clearance (impeller to bottom distance) for Rushton and pitch-blade turbine impellers in a stirred tank bioreactor for improved substrate mixing time added at interface, taking advantage of computational fluid dynamics. In this regard, the time needed for a thin layer of liquid, resembling substrate-rich or poor part, getting homogenously dispersed within the tank was calculated. The mixing time calculated in this way is called the surface aeration related mixing time (SARMT). SARMT was calculated using two approaches and was compared with each other. For the pitch-blade turbine impeller, a criterion which guarantees accurate mixing time by simulation was not satisfied, so the SARMT profile against clearance was not achieved. For the Rushton impeller, a general descending order of SARMT against impeller-bottom clearance was observed.

CFD Simulation of the Particle Dispersion Behavior and Mass Transfer–Reaction Kinetics in non-Newton Fluid with High Viscosity

Solid particle dispersion and chemical reactions in high-viscosity non-Newtonian fluid are commonly encountered in polymerization systems. In this study, an interphase mass transfer model and a finite-rate/eddy-dissipation formulation were integrated into a computational fluid dynamics model to simulate the dispersion behavior of particles and the mass transfer–reaction kinetics in a condensation polymerization-stirred tank reactor. Turbulence fields were obtained using the standard k–ε model and employed to calculate the mixing rate. Cross model was used to characterize the rheological property of the non-Newton fluid. The proposed model was first validated by experimental data in terms of input power. Then, several key operating variables (i.e. agitation speed, viscosity, and particle size) were investigated to evaluate the dispersive mixing performance of the stirred vessel. Simulation showed that a high agitation speed and a low fluid viscosity favored particle dispersions. This study provided useful guidelines for industrial-scale high-viscosity polymerization reactors.

Laminar mixing of non-Newtonian fluids in static mixers: process intensification perspective

Static mixers are widely used in various industrial applications to intensify the laminar mixing of non-Newtonian fluids. Non-Newtonian fluids can be categorized into (1) time-independent, (2) time-dependent, and (3) viscoelastic fluids. Computational fluid dynamics studies on the laminar mixing of viscoelastic fluids are very limited due to the complexity in incorporating the multiple relaxation times and the associated stress tensor into the constitutive equations. This review paper provides recommendations for future research studies while summarizing the key research contributions in the field of non-Newtonian fluid mixing using static mixers. This review discusses the different experimental techniques employed such as electrical resistance tomography, magnetic resonance imaging, planar laser-induced fluorescence, and positron emission particle tracking. A comprehensive overview of the mixing fundamentals, fluid chaos, numerical characterization of fluid stretching, development of pressure drop correlations, and derivations of generalized Reynolds number is also provided in this review paper.

Euler-Lagrange computational fluid dynamics for (bio)reactor scale down: An analysis of organism lifelines

The trajectories, referred to as lifelines, of individual microorganisms in an industrial scale fermentor under substrate limiting conditions were studied using an Euler‐Lagrange computational fluid dynamics approach. The metabolic response to substrate concentration variations along these lifelines provides deep insight in the dynamic environment inside a large‐scale fermentor, from the point of view of the microorganisms themselves. We present a novel methodology to evaluate this metabolic response, based on transitions between metabolic “regimes” that can provide a comprehensive statistical insight in the environmental fluctuations experienced by microorganisms inside an industrial bioreactor. These statistics provide the groundwork for the design of representative scale‐down simulators, mimicking substrate variations experimentally. To focus on the methodology we use an industrial fermentation of Penicillium chrysogenum in a simplified representation, dealing with only glucose gradients, single‐phase hydrodynamics, and assuming no limitation in oxygen supply, but reasonably capturing the relevant timescales. Nevertheless, the methodology provides useful insight in the relation between flow and component fluctuation timescales that are expected to hold in physically more thorough simulations. Microorganisms experience substrate fluctuations at timescales of seconds, in the order of magnitude of the global circulation time. Such rapid fluctuations should be replicated in truly industrially representative scale‐down simulators.

Reactors for High Solid Loading Pretreatment of Lignocellulosic Biomass

The review summarized the types, the geometry, and the design principle of pretreatment reactors at high solid loading of lignocellulose material. Among the reactors used, the explosion reactors and the helical stirring reactors are to be considered as the practical form for high solids loading pretreatment operation; the comminution reactors and the extruder reactors are difficult to be used as an independent unit, but possible to be used in the combined form with other types of reactors. The principles of the pretreatment reactor design at high solid loading were discussed and several basic principles for the design were proposed. This review provided useful information for choosing the reactor types and designing the geometry of pretreatment operation at the high solids loading.