1
|
Xing Z, Duane G, O'Sullivan J, Chelius C, Smith L, Borys MC, Khetan A. Validation of a CFD model for cell culture bioreactors at large scale and its application in scale-up. J Biotechnol 2024; 387:79-88. [PMID: 38582408 DOI: 10.1016/j.jbiotec.2024.02.006] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/27/2023] [Revised: 11/28/2023] [Accepted: 02/18/2024] [Indexed: 04/08/2024]
Abstract
Among all the operating parameters that control the cell culture environment inside bioreactors, appropriate mixing and aeration are crucial to ensure sufficient oxygen supply, homogeneous mixing, and CO2 stripping. A model-based manufacturing facility fit approach was applied to define agitation and bottom air flow rates during the process scale-up from laboratory to manufacturing, of which computational fluid dynamics (CFD) was the core modeling tool. The realizable k-ε turbulent dispersed Eulerian gas-liquid flow model was established and validated using experimental values for the volumetric oxygen transfer coefficient (kLa). Model validation defined the process operating parameter ranges for application of the model, identified mixing issues (e.g., impeller flooding, dissolved oxygen gradients, etc.) and the impact of antifoam on kLa. Using the CFD simulation results as inputs to the models for oxygen demand, gas entrance velocity, and CO2 stripping aided in the design of the agitation and bottom air flow rates needed to meet cellular oxygen demand, control CO2 levels, mitigate risks for cell damage due to shear, foaming, as well as fire hazards due to high O2 levels in the bioreactor gas outlet. The recommended operating conditions led to the completion of five manufacturing runs with a 100% success rate. This model-based approach achieved a seamless scale-up and reduced the required number of at-scale development batches, resulting in cost and time savings of a cell culture commercialization process.
Collapse
Affiliation(s)
- Zizhuo Xing
- Biologics Development and Operations, Bristol Myers Squibb Company, Devens, MA 01434, USA.
| | - Gearóid Duane
- Manufacturing Science and Technology Biologics, Bristol Myers Squibb Company, Mulhuddart, Ireland
| | - Josiah O'Sullivan
- Manufacturing Science and Technology Biologics, Bristol Myers Squibb Company, Mulhuddart, Ireland
| | - Cynthia Chelius
- Biologics Development and Operations, Bristol Myers Squibb Company, Devens, MA 01434, USA
| | - Laura Smith
- Biologics Development and Operations, Bristol Myers Squibb Company, Devens, MA 01434, USA
| | - Michael C Borys
- Biologics Development and Operations, Bristol Myers Squibb Company, Devens, MA 01434, USA.
| | - Anurag Khetan
- Biologics Development and Operations, Bristol Myers Squibb Company, Devens, MA 01434, USA
| |
Collapse
|
2
|
Marx R, Liu H, Yoon S, Xie D. CFD evaluation of hydrophobic feedstock bench-scale fermenters for efficient high agitation volumetric mass transfer. Biotechnol J 2024; 19:e2300384. [PMID: 38403465 DOI: 10.1002/biot.202300384] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/01/2023] [Revised: 12/08/2023] [Accepted: 01/02/2024] [Indexed: 02/27/2024]
Abstract
A new biomanufacturing platform combining intracellular metabolic engineering of the oleaginous yeast Yarrowia lipolytica and extracellular bioreaction engineering provides efficient bioconversion of plant oils/animal fats into high-value products. However, predicting the hydrodynamics and mass transfer parameters is difficult due to the high agitation and sparging required to create dispersed oil droplets in an aqueous medium for efficient yeast fermentation. In the current study, commercial computational fluid dynamic (CFD) solver Ansys CFX coupled with the MUSIG model first predicts two-phase system (oil/water and air/water) mixing dynamics and their particle size distributions. Then, a three-phase model (oil, air, and water) utilizing dispersed air bubbles and a polydispersed oil phase was implemented to explore fermenter mixing, gas dispersion efficiency, and volumetric mass transfer coefficient estimations (kL a). The study analyzed the effect of the impeller type, agitation speed, and power input on the tank's flow field and revealed that upward-pumping pitched blade impellers (PBI) in the top two positions (compared to Rushton-type) provided advantageous oil phase homogeneity and similar estimated kL a values with reduced power. These results show good agreement with the experimental mixing and kL a data.
Collapse
Affiliation(s)
- Richard Marx
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, Massachusetts, USA
| | - Huolong Liu
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, Massachusetts, USA
| | - Seongkyu Yoon
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, Massachusetts, USA
| | - Dongming Xie
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, Massachusetts, USA
| |
Collapse
|
3
|
Jegatheeswaran S, Ein-Mozaffari F. Gas Helicity Yields New Insights into Gas–Liquid Reactor Design: Enhanced Oxygen Transfer Rate of Coaxial Mixers at Low-Speed Ratio. Ind Eng Chem Res 2023. [DOI: 10.1021/acs.iecr.2c04016] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/21/2023]
Affiliation(s)
- Sinthuran Jegatheeswaran
- Department of Chemical Engineering, Toronto Metropolitan University, 350 Victoria Street, Toronto, OntarioM5B 2K3, Canada
| | - Farhad Ein-Mozaffari
- Department of Chemical Engineering, Toronto Metropolitan University, 350 Victoria Street, Toronto, OntarioM5B 2K3, Canada
| |
Collapse
|
4
|
Sharifi F, Behzadfar E, Ein-Mozaffari F. Intensified gas-liquid mixing in bioreactors equipped with a dual coaxial mixer containing biopolymer solutions. Chem Eng Res Des 2023. [DOI: 10.1016/j.cherd.2023.01.026] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/19/2023]
|
5
|
Chen L, Li Y, Chen B, Wang P, Zheng S, Zhang W. CFD modeling of the turbulent dispersion of liquid droplets in a vessel using a correlation based on local droplet size distribution. CHEM ENG COMMUN 2022. [DOI: 10.1080/00986445.2021.1978074] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
Affiliation(s)
- Luming Chen
- Institute of Process Equipment and Control Engineering, College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, China
- Engineering Research Center of Process Equipment and Re-manufacturing, Ministry of Education, Zhejiang University of Technology, Hangzhou, China
| | - Yibin Li
- Institute of Process Equipment and Control Engineering, College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, China
- Engineering Research Center of Process Equipment and Re-manufacturing, Ministry of Education, Zhejiang University of Technology, Hangzhou, China
| | - Bingbing Chen
- Institute of Process Equipment and Control Engineering, College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, China
- Engineering Research Center of Process Equipment and Re-manufacturing, Ministry of Education, Zhejiang University of Technology, Hangzhou, China
| | - Pengfei Wang
- Institute of Process Equipment and Control Engineering, College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, China
- Engineering Research Center of Process Equipment and Re-manufacturing, Ministry of Education, Zhejiang University of Technology, Hangzhou, China
| | - Sanlong Zheng
- Institute of Process Equipment and Control Engineering, College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, China
- Engineering Research Center of Process Equipment and Re-manufacturing, Ministry of Education, Zhejiang University of Technology, Hangzhou, China
| | - Wei Zhang
- Institute of Process Equipment and Control Engineering, College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, China
- Engineering Research Center of Process Equipment and Re-manufacturing, Ministry of Education, Zhejiang University of Technology, Hangzhou, China
| |
Collapse
|
6
|
Scale-up study of aerated coaxial mixing reactors containing non-newtonian power-law fluids: Analysis of gas holdup, cavity size, and power consumption. J IND ENG CHEM 2022. [DOI: 10.1016/j.jiec.2022.06.004] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
|
7
|
Rahimzadeh A, Ein-Mozaffari F, Lohi A. New Insights into the Gas Dispersion and Mass Transfer in Shear-Thinning Fluids Inside an Aerated Coaxial Mixer via Analysis of Flow Hydrodynamics and Shear Environment. Ind Eng Chem Res 2022. [DOI: 10.1021/acs.iecr.1c04586] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Ali Rahimzadeh
- Department of Chemical Engineering, Ryerson University, 350 Victoria Street, Toronto, Ontario M5B 2K3, Canada
| | - Farhad Ein-Mozaffari
- Department of Chemical Engineering, Ryerson University, 350 Victoria Street, Toronto, Ontario M5B 2K3, Canada
| | - Ali Lohi
- Department of Chemical Engineering, Ryerson University, 350 Victoria Street, Toronto, Ontario M5B 2K3, Canada
| |
Collapse
|
8
|
Gas Dispersion in Non-Newtonian Fluids with Mechanically Agitated Systems: A Review. Processes (Basel) 2022. [DOI: 10.3390/pr10020275] [Citation(s) in RCA: 7] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/04/2023] Open
Abstract
Gas dispersion in non-Newtonian fluids is encountered in a broad range of chemical, biochemical, and food industries. Mechanically agitated vessels are commonly employed in these processes because they promote high degree of contact between the phases. However, mixing non-Newtonian fluids is a challenging task that requires comprehensive knowledge of the mixing flow to accurately design stirred vessels. Therefore, this review presents the developments accomplished by researchers in this field. The present work describes mixing and mass transfer variables, namely volumetric mass transfer coefficient, power consumption, gas holdup, bubble diameter, and cavern size. It presents empirical correlations for the mixing variables and discusses the effects of operating and design parameters on the mixing and mass transfer process. Furthermore, this paper demonstrates the advantages of employing computational fluid dynamics tools to shed light on the hydrodynamics of this complex flow. The literature review shows that knowledge gaps remain for gas dispersion in yield stress fluids and non-Newtonian fluids with viscoelastic effects. In addition, comprehensive studies accounting for the scale-up of these mixing processes still need to be accomplished. Hence, further investigation of the flow patterns under different process and design conditions are valuable to have an appropriate insight into this complex system.
Collapse
|
9
|
Local Distribution of Oxygen Mass Transfer Coefficient in CMC Solutions in Bioreactors Furnished with Different Types of Coaxial Mixers. Chem Eng Res Des 2021. [DOI: 10.1016/j.cherd.2021.08.006] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
|
10
|
Hu X, Ilgun AD, Passalacqua A, Fox RO, Bertola F, Milosevic M, Visscher F. CFD simulations of stirred-tank reactors for gas-liquid and gas-liquid-solid systems using OpenFOAM®. INTERNATIONAL JOURNAL OF CHEMICAL REACTOR ENGINEERING 2021. [DOI: 10.1515/ijcre-2019-0229] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Abstract
An open-source CFD software OpenFOAM® is used to simulate two multiphase stirred-tank reactors relevant to industrial processes such as slurry polymerization and fuel production. Gas-liquid simulations are first performed in a single-impeller stirred-tank reactor, studied experimentally by Ford, J. J., T. J. Heindel, T. C. Jensen, and J. B. Drake. 2008. “X-Ray Computed Tomography of a Gas-Sparged Stirred-Tank Reactor.” Chemical Engineering Science 63: 2075–85. Three impeller rotation speeds (200, 350 and 700 rpm) with three different bubble diameters (0.5, 1.5 and 2.5 mm) are investigated. Flow patterns compared qualitatively to those from experiments. Compared to the experimental data, the simulations are in relatively good agreement for gas holdup in the reactor. The second multiphase system is a multi-impeller stirred-tank reactor, studied experimentally by Shewale, S. D., and A. B. Pandit. 2006. “Studies in Multiple Impeller Agitated Gas-Liquid Contractors.” Chemical Engineering Science 61: 486–504. Gas-liquid simulations are performed at two impeller rotation speeds (3.75 and 5.08 RPS). The simulated flow patterns agree with published pictures from the experiments. Gas-liquid-solid simulations of the multi-impeller stirred-tank reactor are also carried out at impeller rotation speed 5.08 RPS. The addition of solid particles with a volume fraction characteristic of slurry reactors changes the flow pattern significantly. The bottom Rushton turbine becomes flooded, while the upper pitched-blade downflow turbines present a radial-pumping flow pattern instead of down-pumping. Nonetheless, the solid phase has a similar flow pattern to the liquid phase, indicating that the particles modify the effective density of the fluid.
Collapse
Affiliation(s)
- Xiaofei Hu
- Department of Mechanical Engineering , Iowa State University , 2529 Union Dr , Ames , IA 50011-2030 , USA
| | - Aziz Dogan Ilgun
- Department of Mechanical Engineering , Iowa State University , 2529 Union Dr , Ames , IA 50011-2030 , USA
- Department of Chemical and Biological Engineering , Iowa State University , 618 Bissell Rd , Ames , IA 50011-1098 , USA
| | - Alberto Passalacqua
- Department of Mechanical Engineering , Iowa State University , 2529 Union Dr , Ames , IA 50011-2030 , USA
| | - Rodney O. Fox
- Department of Chemical and Biological Engineering , Iowa State University , 618 Bissell Rd , Ames , IA 50011-1098 , USA
| | - Francesco Bertola
- SABIC , Urmonderbaan 22 , P.O. Box 319 , 6160 AH , Geleen , The Netherlands
| | - Miran Milosevic
- SABIC , Urmonderbaan 22 , P.O. Box 319 , 6160 AH , Geleen , The Netherlands
| | - Frans Visscher
- SABIC , Urmonderbaan 22 , P.O. Box 319 , 6160 AH , Geleen , The Netherlands
| |
Collapse
|
11
|
Two-fluids RANS predictions of gas cavities, power consumption, mixing time and oxygen transfer rate in an aerated fermenter scale-down stirred with multiple impellers. Biochem Eng J 2021. [DOI: 10.1016/j.bej.2020.107867] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/27/2022]
|
12
|
Zheng H, Yan Z, Zhu X, Yan Z. Hydrodynamics and flow-accelerated corrosion in a stirred crystallizer: Experiment and simulation. J Taiwan Inst Chem Eng 2021. [DOI: 10.1016/j.jtice.2021.01.002] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
|
13
|
Jamshidzadeh M, Ein‐Mozaffari F, Lohi A. Local and overall gas holdup in an aerated coaxial mixing system containing a non‐
Newtonian
fluid. AIChE J 2020. [DOI: 10.1002/aic.17016] [Citation(s) in RCA: 16] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Maryam Jamshidzadeh
- Department of Chemical Engineering Ryerson University Toronto Ontario Canada
| | | | - Ali Lohi
- Department of Chemical Engineering Ryerson University Toronto Ontario Canada
| |
Collapse
|
14
|
Numerical simulation of micro-mixing in gas–liquid and solid–liquid stirred tanks with the coupled CFD-E-model. Chin J Chem Eng 2020. [DOI: 10.1016/j.cjche.2020.06.016] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
|
15
|
Abstract
The mixing process in a mechanically agitated vessel is a widespread phenomenon which plays an important role among industrial processes. In that process, one of the crucial parameters, the mixing efficiency, depends on a large number of geometrical factors, as well as process parameters and complex interactions between the phases which are still not well understood. In the last decade, large progress has been made in optimisation, construction and numerical and experimental analysis of mechanically agitated vessels. In this review, the current state in this field has been presented. It shows that advanced computational fluid dynamic techniques for multiphase flow analysis with reactions and modern experimental techniques can be used with success to analyse in detail mixing features in liquid-liquid, gas-liquid, solid-liquid and in more than two-phase flows. The objective is to show the most important research recently carried out.
Collapse
|
16
|
Numerical and experimental analyses of a stirred vessel for a large volumetric flow rate of sparged air. Chin J Chem Eng 2019. [DOI: 10.1016/j.cjche.2019.03.009] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
|
17
|
Zheng C, Guo J, Wang C, Chen Y, Zheng H, Yan Z, Chen Q. Experimental study and simulation of a three-phase flow stirred bioreactor. Chin J Chem Eng 2019. [DOI: 10.1016/j.cjche.2018.06.010] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/01/2022]
|
18
|
Li X, Scott K, Kelly WJ, Huang Z. Development of a Computational Fluid Dynamics Model for Scaling-up Ambr Bioreactors. BIOTECHNOL BIOPROC E 2018. [DOI: 10.1007/s12257-018-0063-5] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
|
19
|
Liangchao L, Ning C, Kefeng X, Beiping X. A Comparative CFD Study on Gas-Liquid Dispersion in A Stirred Tank with Low and High Gas Loadings. INTERNATIONAL JOURNAL OF CHEMICAL REACTOR ENGINEERING 2018. [DOI: 10.1515/ijcre-2017-0147] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Abstract
The computational fluid dynamics (CFD) combined with a population balance model (PBM) was applied to simulate gas-liquid dispersion in a stirred tank with low and high gas loadings. The model predictions were validated by using the data in the literature. The simulation results show that the flow patterns and gas dispersion characteristics are very different in the stirred tank for low and high gas loadings. A typical two-loop flow pattern forms as that in single-phase stirred tank for low gas loadings, while a triple-loop flow pattern, with two recirculation loops above and one below the impeller is found in the tank for high gas loadings. Shaft power input of impeller agitation plays a major role for gas dispersion with low gas loadings. For high gas loadings, the potential energy due to gas sparging has significant effect on gas dispersion and can not be neglected. Compared to low gas loading, high gas loading causes average gas holdup increased in the stirred tank, while relative local gas holdup in the lower circulation-loop region and near-wall region reduced. The ability of impeller agitation for gas dispersion reduces with high gas loadings, and mean bubble size becomes larger and the volume-averaged bubble size distribution is wider.
Collapse
|
20
|
Kazemzadeh A, Elias C, Tamer M, Ein-Mozaffari F. Hydrodynamic performance of a single-use aerated stirred bioreactor in animal cell culture: applications of tomography, dynamic gas disengagement (DGD), and CFD. Bioprocess Biosyst Eng 2018; 41:679-695. [PMID: 29445862 DOI: 10.1007/s00449-018-1902-7] [Citation(s) in RCA: 24] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/20/2017] [Accepted: 01/27/2018] [Indexed: 11/28/2022]
Abstract
The hydrodynamics of gas-liquid two-phase flow in a single-use bioreactor were investigated in detail both experimentally and numerically. Electrical resistance tomography (ERT) and dynamic gas disengagement (DGD) combined with computational fluid dynamics (CFD) were employed to assess the effect of the volumetric gas flow rate and impeller speed on the gas-liquid flow field, local and global gas holdup values, and Sauter mean bubble diameter. From the results obtained from DGD coupled with ERT, the bubble sizes were determined. The experimental data indicated that the total gas holdup values increased with increasing both the rotational speed of impeller and volumetric gas flow rate. Moreover, the analysis of the flow field generated inside the aerated stirred bioreactor was conducted using CFD results. Overall, a more uniform distribution of the gas holdup was obtained at impeller speeds ≥ 100 rpm for volumetric gas flow rates ≥ 1.6 × 10-5 m3/s.
Collapse
Affiliation(s)
- Argang Kazemzadeh
- Department of Chemical Engineering, Ryerson University, 350 Victoria Street, Toronto, M5B 2K3, Canada
| | - Cynthia Elias
- Sanofi Pasteur Company, 1755 Steels Avenue West, North York, Toronto, M2R 3T4, Canada
| | - Melih Tamer
- Sanofi Pasteur Company, 1755 Steels Avenue West, North York, Toronto, M2R 3T4, Canada
| | - Farhad Ein-Mozaffari
- Department of Chemical Engineering, Ryerson University, 350 Victoria Street, Toronto, M5B 2K3, Canada.
| |
Collapse
|
21
|
Li L, Chen N, Xiang K, Xiang B. CFD simulation of hydrodynamics characteristics in a tank stirred by a hollow self-inducing impeller. CAN J CHEM ENG 2018. [DOI: 10.1002/cjce.23135] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Liangchao Li
- Key Laboratory of Testing Technology for Manufacturing Process of Ministry of Education, School of Manufacturing Science and Engineering; Southwest University of Science and Technology; Mianyang Sichuan 621010 P. R. China
| | - Ning Chen
- Yinhe Constructional and Chemicals Group Co., Ltd., Anxian; Sichuan 622656 P. R. China
| | - Kefeng Xiang
- Key Laboratory of Testing Technology for Manufacturing Process of Ministry of Education, School of Manufacturing Science and Engineering; Southwest University of Science and Technology; Mianyang Sichuan 621010 P. R. China
| | - Beiping Xiang
- Key Laboratory of Testing Technology for Manufacturing Process of Ministry of Education, School of Manufacturing Science and Engineering; Southwest University of Science and Technology; Mianyang Sichuan 621010 P. R. China
| |
Collapse
|
22
|
Khalili F, Jafari Nasr M, Kazemzadeh A, Ein-Mozaffari F. Hydrodynamic performance of the ASI impeller in an aerated bioreactor containing the biopolymer solution through tomography and CFD. Chem Eng Res Des 2017. [DOI: 10.1016/j.cherd.2017.07.016] [Citation(s) in RCA: 18] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
|
23
|
Li X, Guan X, Zhou R, Yang N, Liu M. CFD Simulation of Gas Dispersion in a Stirred Tank of Dual Rushton Turbines. INTERNATIONAL JOURNAL OF CHEMICAL REACTOR ENGINEERING 2017. [DOI: 10.1515/ijcre-2016-0221] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Abstract3D Eulerian-Eulerian model was applied to simulate the gas-liquid two-phase flow in a stirred tank of dual Rushton turbines using computational fluid dynamics (CFD). The effects of two different bubble treatment methods (constant bubble sizevs. population balance model, PBM) and two different coalescence models (Luo modelvs. Zaichik model) on the prediction of liquid flow field, local gas holdup or bubble size distribution were studied. The results indicate that there is less difference between the predictions of liquid flow field and gas holdup using the above models, and the use of PBM did not show any advantage over the constant bubble size model under lower gas holdup. However, bubble treatment methods have great influence on the local gas holdup under larger gas flow rate. All the models could reasonably predict the gas holdup distribution in the tank operated at a low aeration rate except the region far from the shaft. Different coalescence models have great influence on the prediction of bubble size distribution (BSD). Both the Luo model and Zaichik model could qualitatively estimate the BSD, showing the turning points near the impellers along the height, but the quantitative agreement with experiments is not achieved. The former over-predicts the BSD and the latter under-predicts, showing that the existing PBM models need to be further developed to incorporate more physics.
Collapse
|
24
|
ZHOU XUELING, LIU YIFAN, YU WEN, CHENG SHAOJIE, YIN JIANZHONG. SIMULATION OF SOLID–LIQUID SUSPENSION AND SCALE-UP OF AGAROSE GEL ACTIVATION REACTOR. J MECH MED BIOL 2016. [DOI: 10.1142/s0219519416500871] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
Abstract
Agarose gel activation reaction, which is of great importance in preparing the carrier of the column packing material for blood purification, would be significantly influenced by the configuration and parameter of reactor. In order to optimize the structure design of the reactor and operating parameters of the process, the characteristics of suspension system composed of agarose gel, NaOH, water, 3-allyl bromide, and activated alumina were simulated numerically utilizing an Eulerian multiphase flow model and multi-reference frame (MRF) approach. The effect of impeller configuration was studied with three typical impellers, including Rushton disk turbine (DT), pitched blade downflow turbine (PBTD45), and pitched blade upflow turbine (PBTU45). The results showed that the optimum solid suspension was obtained using PBTD45 impeller with a diameter of 100[Formula: see text]mm and critical suspension speed of 570[Formula: see text]rpm in a 20[Formula: see text]L stirred reactor. In addition, the critical suspension speeds using the three impellers were calculated and the errors were all within the engineering allowance. Finally, the feasibility of scale-up design for agarose gel activation reactor was preliminarily discussed. The results would be useful to the optimization and scale-up of relevant reactor design.
Collapse
Affiliation(s)
- XUELING ZHOU
- State Key Laboratory of Fine Chemicals, Dalian University of Technology, Dalian 116024, P. R. China
| | - YIFAN LIU
- School of Chemical Machinery, State Key Laboratory of Fine Chemicals, Dalian 116024, P. R. China
| | - WEN YU
- School of Chemical Machinery, State Key Laboratory of Fine Chemicals, Dalian 116024, P. R. China
| | - SHAOJIE CHENG
- School of Chemical Machinery, State Key Laboratory of Fine Chemicals, Dalian 116024, P. R. China
| | - JIANZHONG YIN
- State Key Laboratory of Fine Chemicals, School of Chemical Machinery, Dalian University of Technology, Dalian 116024, P. R. China
| |
Collapse
|
25
|
Chen M, Wang J, Zhao S, Xu C, Feng L. Optimization of Dual-Impeller Configurations in a Gas–Liquid Stirred Tank Based on Computational Fluid Dynamics and Multiobjective Evolutionary Algorithm. Ind Eng Chem Res 2016. [DOI: 10.1021/acs.iecr.6b01660] [Citation(s) in RCA: 14] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Miaona Chen
- State Key
Laboratory of Chemical
Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, PR China
| | - Jiajun Wang
- State Key
Laboratory of Chemical
Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, PR China
| | - Siwei Zhao
- State Key
Laboratory of Chemical
Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, PR China
| | - Chaozhong Xu
- State Key
Laboratory of Chemical
Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, PR China
| | - Lianfang Feng
- State Key
Laboratory of Chemical
Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, PR China
| |
Collapse
|
26
|
See TY, Abdul Raman AA, Raja Ehsan Shah RSS, Ibrahim S, Mohamad Nor MI. Study of sparger location on solid suspension in a triple-impeller stirred vessel. ASIA-PAC J CHEM ENG 2015. [DOI: 10.1002/apj.1959] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Tiam You See
- Department of Chemical Engineering, Faculty Engineering; University of Malaya; 50603 Kuala Lumpur Malaysia
| | - Abdul Aziz Abdul Raman
- Department of Chemical Engineering, Faculty Engineering; University of Malaya; 50603 Kuala Lumpur Malaysia
| | | | - Shaliza Ibrahim
- Department of Civil Engineering, Faculty Engineering; University of Malaya; 50603 Kuala Lumpur Malaysia
| | | |
Collapse
|
27
|
|
28
|
Devi TT, Kumar B. Scale up criteria for dual stirred gas-liquid unbaffled tank with concave blade impeller. KOREAN J CHEM ENG 2014. [DOI: 10.1007/s11814-014-0090-7] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
|
29
|
Wang Z, Cheng Z, Huang Z, Yu K, Li X, Xin R, Long Y, Wang D, Wang G, Wang S, Li S. Intensified Gas–Liquid Mixing in a Quench Box under the Driving of Supergravitational Swirling Flow. Ind Eng Chem Res 2013. [DOI: 10.1021/ie400639r] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Zhenyuan Wang
- State Key Laboratory
of Chemical Engineering, East China University of Science and Technology, Shanghai
200237, People’s Republic of China
| | - Zhenmin Cheng
- State Key Laboratory
of Chemical Engineering, East China University of Science and Technology, Shanghai
200237, People’s Republic of China
| | - Zibin Huang
- State Key Laboratory
of Chemical Engineering, East China University of Science and Technology, Shanghai
200237, People’s Republic of China
| | - Kun Yu
- State Key Laboratory
of Chemical Engineering, East China University of Science and Technology, Shanghai
200237, People’s Republic of China
| | - Xuehua Li
- East China Design Institute, Chinese Natural Petroleum Corporation, Qingdao 266071, People’s
Republic of China
| | - Ruokai Xin
- East China Design Institute, Chinese Natural Petroleum Corporation, Qingdao 266071, People’s
Republic of China
| | - Yu Long
- East China Design Institute, Chinese Natural Petroleum Corporation, Qingdao 266071, People’s
Republic of China
| | - Dehui Wang
- East China Design Institute, Chinese Natural Petroleum Corporation, Qingdao 266071, People’s
Republic of China
| | - Guoqi Wang
- East China Design Institute, Chinese Natural Petroleum Corporation, Qingdao 266071, People’s
Republic of China
| | - Shuxu Wang
- East China Design Institute, Chinese Natural Petroleum Corporation, Qingdao 266071, People’s
Republic of China
| | - Shengshan Li
- East China Design Institute, Chinese Natural Petroleum Corporation, Qingdao 266071, People’s
Republic of China
| |
Collapse
|
30
|
|
31
|
Devi TT, Kumar B. Comparison of flow patterns of dual rushton and CD-6 impellers. THEORETICAL FOUNDATIONS OF CHEMICAL ENGINEERING 2013. [DOI: 10.1134/s0040579513040210] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
|
32
|
Experimental study and numerical simulation of local void fraction in cold-gassed and hot-sparged stirred reactors. Chem Eng Sci 2013. [DOI: 10.1016/j.ces.2013.02.005] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
|
33
|
Aguilera-Alvarado AF, Pérez-Alonso R, Cano-Rodríguez MI, Uribe-Ramírez AR, Aguilar-Pérez GE, Lugo-Martínez JR. CFD Study of the Weeping and Flooding Effects in a Nonsymmetrical Sparger in a Stirred Tank. Ind Eng Chem Res 2013. [DOI: 10.1021/ie302754m] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Alberto F. Aguilera-Alvarado
- Department of Chemical Engineering, University of Guanajuato, Col. Noria Alta S/N, C.P. 36050, Guanajuato,
Guanajuato, México
| | - Raúl Pérez-Alonso
- Department of Chemical Engineering, University of Guanajuato, Col. Noria Alta S/N, C.P. 36050, Guanajuato,
Guanajuato, México
| | - M. Irene Cano-Rodríguez
- Department of Chemical Engineering, University of Guanajuato, Col. Noria Alta S/N, C.P. 36050, Guanajuato,
Guanajuato, México
| | - Agustín R. Uribe-Ramírez
- Department of Chemical Engineering, University of Guanajuato, Col. Noria Alta S/N, C.P. 36050, Guanajuato,
Guanajuato, México
| | - G. Enrique Aguilar-Pérez
- Department of Chemical Engineering, University of Guanajuato, Col. Noria Alta S/N, C.P. 36050, Guanajuato,
Guanajuato, México
| | - Jesús R. Lugo-Martínez
- Department of Chemical Engineering, University of Guanajuato, Col. Noria Alta S/N, C.P. 36050, Guanajuato,
Guanajuato, México
| |
Collapse
|
34
|
Ranganathan P, Sivaraman S. Investigations on hydrodynamics and mass transfer in gas–liquid stirred reactor using computational fluid dynamics. Chem Eng Sci 2011. [DOI: 10.1016/j.ces.2011.03.007] [Citation(s) in RCA: 55] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/18/2022]
|
35
|
Computational fluid dynamics modeling of gas dispersion in multi impeller bioreactor. J Biosci Bioeng 2010; 109:588-97. [DOI: 10.1016/j.jbiosc.2009.11.014] [Citation(s) in RCA: 53] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/09/2009] [Revised: 11/02/2009] [Accepted: 11/18/2009] [Indexed: 11/21/2022]
|
36
|
|
37
|
Zhang H, Zhang K, Fan S. CFD simulation coupled with population balance equations for aerated stirred bioreactors. Eng Life Sci 2009. [DOI: 10.1002/elsc.200800074] [Citation(s) in RCA: 41] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022] Open
|
38
|
CHEN L, BAO Y, GAO Z. Void Fraction Distributions in Cold-gassed and Hot-parged Three Phase Stirred Tanks with Multi-impeller. Chin J Chem Eng 2009. [DOI: 10.1016/s1004-9541(08)60293-1] [Citation(s) in RCA: 8] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
|
39
|
Zhao FY, Liu D, Tang GF. Inverse determination of boundary heat fluxes in a porous enclosure dynamically coupled with thermal transport. Chem Eng Sci 2009. [DOI: 10.1016/j.ces.2008.12.005] [Citation(s) in RCA: 18] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
|
40
|
|
41
|
Panneerselvam R, Savithri S, Surender GD. CFD modeling of gas–liquid–solid mechanically agitated contactor. Chem Eng Res Des 2008. [DOI: 10.1016/j.cherd.2008.08.008] [Citation(s) in RCA: 53] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
|
42
|
Huang Q, Yang C, Yu G, Mao ZS. Sensitivity Study on Modeling an Internal Airlift Loop Reactor Using a Steady 2D Two-Fluid Model. Chem Eng Technol 2008. [DOI: 10.1002/ceat.200700278] [Citation(s) in RCA: 25] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
|
43
|
Min J, Bao Y, Chen L, Gao Z, Smith JM. Numerical Simulation of Gas Dispersion in an Aerated Stirred Reactor with Multiple Impellers. Ind Eng Chem Res 2008. [DOI: 10.1021/ie800490j] [Citation(s) in RCA: 23] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Jian Min
- School of Chemical Engineering, Beijing University of Chemical Technology, Beijing 100029, China and Fluids and Systems Research Centre, School of Engineering (J2), University of Surrey, Guildford GU2 7XH, United Kingdom
| | - Yuyun Bao
- School of Chemical Engineering, Beijing University of Chemical Technology, Beijing 100029, China and Fluids and Systems Research Centre, School of Engineering (J2), University of Surrey, Guildford GU2 7XH, United Kingdom
| | - Lei Chen
- School of Chemical Engineering, Beijing University of Chemical Technology, Beijing 100029, China and Fluids and Systems Research Centre, School of Engineering (J2), University of Surrey, Guildford GU2 7XH, United Kingdom
| | - Zhengming Gao
- School of Chemical Engineering, Beijing University of Chemical Technology, Beijing 100029, China and Fluids and Systems Research Centre, School of Engineering (J2), University of Surrey, Guildford GU2 7XH, United Kingdom
| | - John M. Smith
- School of Chemical Engineering, Beijing University of Chemical Technology, Beijing 100029, China and Fluids and Systems Research Centre, School of Engineering (J2), University of Surrey, Guildford GU2 7XH, United Kingdom
| |
Collapse
|
44
|
CFD simulation of gas–liquid flows in stirred vessel equipped with dual rushton turbines: influence of parallel, merging and diverging flow configurations. Chem Eng Sci 2008. [DOI: 10.1016/j.ces.2008.04.039] [Citation(s) in RCA: 41] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
|
45
|
Xia JY, Wang SJ, Zhang SL, Zhong JJ. Computational investigation of fluid dynamics in a recently developed centrifugal impeller bioreactor. Biochem Eng J 2008. [DOI: 10.1016/j.bej.2007.08.006] [Citation(s) in RCA: 27] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
|
46
|
Murthy B, Ghadge R, Joshi J. CFD simulations of gas–liquid–solid stirred reactor: Prediction of critical impeller speed for solid suspension. Chem Eng Sci 2007. [DOI: 10.1016/j.ces.2007.07.005] [Citation(s) in RCA: 118] [Impact Index Per Article: 6.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
|
47
|
Numerical Simulation of Gas Holdup Distribution in a Standard Rushton Stirred Tank Using Discrete Particle Method. Chin J Chem Eng 2007. [DOI: 10.1016/s1004-9541(08)60007-5] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
|
48
|
Montante G, Paglianti A, Magelli F. Experimental Analysis and Computational Modelling of Gas–Liquid Stirred Vessels. Chem Eng Res Des 2007. [DOI: 10.1205/cherd06141] [Citation(s) in RCA: 52] [Impact Index Per Article: 3.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
|
49
|
Van den Akker HE. The Details of Turbulent Mixing Process and their Simulation. COMPUTATIONAL FLUID DYNAMICS 2006. [DOI: 10.1016/s0065-2377(06)31003-4] [Citation(s) in RCA: 27] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/29/2023]
|