Macro- and micromixing studies in an unbaffled vessel agitated by a Rushton turbine

Computational Fluid Dynamics Study of a Pharmaceutical Full-Scale Hydrogenation Reactor

The pharmaceutical industry has been quite successful in developing new hydrogenation processes, and the chemistry of hydrogenation is currently well understood. However, it is a complex process to scale and optimize due to its high exothermicity, use of expensive catalysts and solvents, and its mass transfer requirements. Therefore, the aim of this work is to develop a CFD model to be able to describe the mass transfer, hydrodynamics, and mixing with respect to changes in rotational speed for a full-scale pharmaceutical hydrogenation reactor. In the first stage, a simple CFD model is used to predict the development of the surface vortex, and it is validated against literature data. In the second stage, the CFD model is tested on a full-scale configuration equipped with a Rushton turbine and a bottom kicker to study the formation of the surface vortex. Simulation results show the ability to predict the development of the surface vortex. These results are used to estimate the liquid height and mixing time as a function of several rotational speeds, allowing us to propose novel process correlations for this particular configuration. Although modelling the complete hydrogenation process would be challenging, this work is seen as a first step towards developing models that demonstrate the use of CFD at such large reactor scales.

Transition from static culture to stirred tank bioreactor for the allogeneic production of therapeutic discogenic cell spheres

Background

Culturing cells as cell spheres results in a tissue-like environment that drives unique cell phenotypes, making it useful for generating cell populations intended for therapeutic use. Unfortunately, common methods that utilize static suspension culture have limited scalability, making commercialization of such cell therapies challenging. Our team is developing an allogeneic cell therapy for the treatment of lumbar disc degeneration comprised of discogenic cells, which are progenitor cells expanded from human nucleus pulposus cells that are grown in a sphere configuration.

Methods

We evaluate sphere production in Erlenmeyer, horizontal axis wheel, stirred tank bioreactor, and rocking bag format. We then explore the use of ramped agitation profiles and computational fluid dynamics to overcome obstacles related to cell settling and the undesired impact of mechanical forces on cell characteristics. Finally, we grow discogenic cells in stirred tank reactors (STRs) and test outcomes in vitro (potency via aggrecan production and identity) and in vivo (rabbit model of disc degeneration).

Results

Computation fluid dynamics were used to model hydrodynamic conditions in STR systems and develop statistically significant correlations to cell attributes including potency (measured by aggrecan production), cell doublings, cell settling, and sphere size. Subsequent model-based optimization and testing resulted in growth of cells with comparable attributes to the original static process, as measured using both in vitro and in vivo models. Maximum shear rate (1/s) was maintained between scales to demonstrate feasibility in a 50 L STR (200-fold scale-up).

Conclusions

Transition of discogenic cell production from static culture to a stirred-tank bioreactor enables cell sphere production in a scalable format. This work shows significant progress towards establishing a large-scale bioprocess methodology for this novel cell therapy that can be used for other, similar cell therapies.

Supplementary Information

The online version contains supplementary material available at 10.1186/s13287-021-02525-0.

An overview of drive systems and sealing types in stirred bioreactors used in biotechnological processes

No matter the scale, stirred tank bioreactors are the most commonly used systems in biotechnological production processes. Single-use and reusable systems are supplied by several manufacturers. The type, size, and number of impellers used in these systems have a significant influence on the characteristics and designs of bioreactors. Depending on the desired application, classic shaft-driven systems, bearing-mounted drives, or stirring elements that levitate freely in the vessel may be employed. In systems with drive shafts, process hygiene requirements also affect the type of seal used. For sensitive processes with high hygienic requirements, magnetic-driven stirring systems, which have been the focus of much research in recent years, are recommended. This review provides the reader with an overview of the most common agitation and seal types implemented in stirred bioreactor systems, highlights their advantages and disadvantages, and explains their possible fields of application. Special attention is paid to the development of magnetically driven agitators, which are widely used in reusable systems and are also becoming more and more important in their single-use counterparts.

Key Points

• Basic design of the most frequently used bioreactor type: the stirred tank bioreactor

• Differences in most common seal types in stirred systems and fields of application

• Comprehensive overview of commercially available bioreactor seal types

• Increased use of magnetically driven agitation systems in single-use bioreactors

Digital Twinning Process for Stirred Tank Reactors/Separation Unit Operations through Tandem Experimental/Computational Fluid Dynamics (CFD) Simulations

Computational fluid dynamics simulations (CFD) were used to evaluate mixing in baffled and unbaffled vessels. The Reynolds-averaged Navier−Stokes k–ε model was implemented in OpenFOAM for obtaining the fluid flow field. The 95% homogenization times were determined by tracer tests. Experimental tests were conducted by injecting sodium chloride into the vessel and measuring the conductivity with two conductivity probes, while the simulations replicated the experimental conditions with the calculation of the transport of species. It was found that the geometry of the system had a great effect on the mixing time, since the irregular flow distribution, which can be obtained with baffles, can lead to local stagnation zones, which will increase the time needed to achieve the homogenization of the solute. It was also found that measuring local, pointwise concentrations can lead to a high underestimation of the global mixing time required for the homogenization of the entire vessel. Dissolution of sucrose was also studied experimentally and by mathematical modeling. The dissolution of sucrose was found to be kinetically limited and a very good agreement was found between the experiments and the modeling approach. The extent of the applicability of CFD simulations was evaluated for enabling rapid process design via simulations.

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.

Micromixing Characteristics in an Aerated Stirred Tank with Half Elliptical Blade Disk Turbine

The parallel-competing iodide-iodate reaction scheme was used to investigate the micromixing efficiency in an aerated stirred tank of 0.30 m diameter agitated by a half elliptical blade disk turbine. The mean specific energy dissipation rate Pm ranged from 0.5 to 2.2 W/kg, while the superficial gas velocity VS ranged from 0.015 to 0.047 m/s. Four sub-surface feed positions were considered. When the tank is fed just under the liquid surface or in the near-wall region, the micromixing efficiency can be enhanced by introducing gases with superficial gas velocities higher than 0.031 m/s. The effects of gas on the micromixing performance become complicated, while the tank is fed in the impeller discharging region. The increase of gas flow rate does not always have good effects on the micromixing performance. Moreover, the way to feed sulfuric acid can strongly affect the efficiency of the reaction scheme. For a single liquid phase, the micromixing time tm according to the incorporation model varies from 5 × 10−3 to 3 × 10−2 s. The dimensionless local specific energy dissipation rate Φ near the liquid surface is almost independent of Pm, while Φ in the impeller discharging area decreases with increasing Pm.

Liquid Flow and Mixing in Bottom Regions of Baffled and Unbaffled Vessels Agitated by Turbine-Type Impeller

For a vessel agitated by the turbine-type impeller, the liquid flow and mixing in the bottom region were studied for comparison between conditions with and without baffles. Visualization of the flow and its measurement were done using particle tracking velocimetry. The flow along the bottom surface of the unbaffled vessel was observed to be more intensified than that of the baffled one. The related local energy dissipation was larger and the effective energy transmission was indicated for the condition without the baffles. For the unbaffled vessel, enhancement of micromixing near the bottom was demonstrated through a mixing experiment in a system involving chemical reactions.