CFD simulation and experimental measurement of gas holdup and liquid interstitial velocity in internal loop airlift reactor

P3HB from CH4 using methanotrophs: aspects of bioreactor, fermentation process and modelling for cost-effective biopolymer production

P3HB (poly-β-hydroxybutyrate), an energy-storage compound of several microorganisms, can be used as bioplastics material. P3HB is completely biodegradable under aerobic and aerobic conditions, also in the marine environment. The intracellular agglomeration of P3HB was examined employing a methanotrophic consortium. Supplanting fossil, non-degradable polymers by P3HB can significantly reduce the environmental impact of plastics. Utilizing inexpensive carbon sources like CH₄ (natural gas, biogas) is a fundamental methodology to make P3HB production less costly, and to avoid the use of primary agricultural products such as sugar or starch. Biomass growth in polyhydroxyalkanoates (PHA) in general and in Poly (3-hydroxybutyrate) manufacture in specific could be a foremost point, so here the authors focus on natural gas as a proper carbon source and on the selection of bioreactors to produceP3HB, and in future further PHA, from that substrate. CH₄ can also be obtained from biomass, e.g., biogas, syngas methanation or power-to-gas (synthetic natural gas, SNG). Simulation software can be utilized for examination, optimizing and scale-up of the process as shown in this paper. The fermentation systems continuously stirred tank reactor (CSTR), forced-liquid vertical loop bioreactor (VTLB), forced-liquid horizontal tubular loop bioreactor (HTLB), airlift (AL) fermenter and bubble column (BC) fermenter were compared for their methane conversion, kLa value, productivity, advantages and disadvantages. Methane is compared to methanol and other feedstocks. It was discovered that under optimum processing circumstances and using Methylocystis hirsuta, the cells accumulated 51.6% cell dry mass of P3HB in the VTLB setup.

A Turbulent Mass Diffusivity Model for Predicting Species Concentration Distribution in the Biodegradation of Phenol Wastewater in an Airlift Reactor

In this study, a three-dimensional CFD transient model is established for predicting species concentration distribution in the biodegradation of phenol in an airlift reactor (ALR). The gas–liquid flow in the ALR is determined by the Euler–Euler method coupled with the standard k-ε model, and the bubble size is predicted by the population balance model (PBM). A turbulent mass diffusivity model is developed to simulate the turbulent mass transfer process and to predict the species concentration distribution. No empirical methods are needed as the turbulent mass diffusivity can be expressed by the concentration variance c2¯ and its dissipation rate εc. A good agreement is found between simulated and experimental results in the literature. It is not reasonable to assume a constant turbulent Schmidt number because the calculated distribution of turbulent mass diffusivity is not identical to that of turbulent viscosity. Finally, the hydrodynamic characteristics and biodegradation performance of the proposed model in a novel ALR are compared with that in the original ALR.

Hydrodynamics and mass transfer of concentric-tube internal loop airlift reactors: A review

The concentric-tube internal loop airlift reactor is a typical reactor configuration which has been adopted for a myriad of chemical and biological processes. The reactor hydrodynamics (including mixing) and the mass transfer between the gas and liquid phases remarkably affect the operational conditions and thus are crucial to the overall reactor performance. Hence, this study aims at providing a thorough description of the basic concepts and a comprehensive review of the relevant reported studies on the hydrodynamics and mass transfer of the concentric-tube internal loop airlift reactors, taking microalgae cultivation as an exemplary application. In particular, the reactor characteristics, geometry, CFD modeling, experimental characterization, and scale up considerations are elucidated. The research gaps for future research and development are also identified.

Industrial Case-Study-Based Computational Fluid Dynamic (CFD) Modeling of Stirred and Aerated Bioreactors

Industrial bioreactors featuring inadequate geometry and operating conditions may depress the effectiveness and the efficiency of the hosted bioprocess. Computational fluid dynamics (CFD) can be used to find a suitable operating match between the target bioprocess and the available bioreactor. The aim of this work is to investigate the feasibility of addressing bioreactor improvement problems in the bioprocess industry with the aid of such mainstream tools as industry-standard CFD. This study illustrates how to effectively simulate both the impeller rotation and air supply and discusses the way toward model validation at the 4.1 m³ capacity scale. Referring to experimentally measured process values, the developed full-scale model successfully predicted the power draw, liquid phase level, and mixing time with errors lower than 4.6, 1.1, and 6.7%, respectively, thus suggesting the illustrated approach as a best practice design method for the bioprocess industry. The validated model was employed to improve performance by reducing the power draw in aerated conditions with a minimal operational derating.

Computational Fluid Dynamics Simulation of Hydrodynamics in a Two-Stage Internal Loop Airlift Reactor with Contraction-Expansion Guide Vane

Global circulation and liquid back mixing adversely affect the continuous production of a multistage internal airlift loop reactor. A contraction-expansion guide vane (CEGV) is proposed and combined with a two-stage internal loop airlift reactor (TSILALR) to suppress the liquid back mixing between stages. A computational fluid dynamics (CFD) simulation is conducted to evaluate the performance of the CEGV in the TSILALR. The bubble size distribution and turbulent flow properties in the TSILALR are considered in the CFD simulation by using the population balance model and RNG k-ε turbulence model. The CFD model is validated against the experimental results. The deviations in the gas holdup and mean bubble diameter between the simulation and experimental results are less than 8% and 6%, respectively. The streamlines, flow pattern, bubble size distribution, and axial liquid velocity in the TSILALRs with and without the CEGV at superficial velocities of 0.04 and 0.08 m/s are obtained by CFD simulation. It has been shown that the CEGV generated local circulation flows at each stage instead of a global circulation flow in the TSILALR. The average global gas holdup in the TSILALR with a CEGV increased up to 1.98 times. The global gas holdup increased from 0.045 to 0.101 and the average axial velocity in the riser decreased from 0.314 to 0.241 m/s when the width of the CEGV increased from 50 to 75 mm at the superficial gas velocity of 0.08 m/s.

Novel external-loop-airlift milliliter scale bioreactors for cell growth studies: Low cost design, CFD analysis and experimental characterization

Many researchers have limited access to fully equipped laboratory-scale batch bioreactors and chemostats due to their relatively high cost. This becomes particularly prohibitive when multiple replicas of the same experiment are required, but not enough bioreactors are available to operate simultaneously. Additionally, experiments using shaken flasks are common but show significant limitations in terms of maintaining homogeneous conditions in liquid cultures or installing instrumentation for monitoring. Here, we proposed to tackle this significant hurdle by providing a route to make available the manufacture of low-cost, milliliter-scale bioreactors. This approach seems plausible for enabling proof-of-concept experiments before moving to a larger scale without significant investments. The conceptually designed systems were based on external-loop bioreactors due to their flexibility, simplicity, and ease of assembling and testing. Designs were initially evaluated in silico with the aid of COMSOL Multiphysics. The successfully evaluated systems were then constructed via additive manufacturing and assembled for hydrodynamics testing via tracer methods. This was enabled by a newly home-made optical absorbance sensor (OAS) for in-line and real-time measurements. Both the in silico and experimental results indicated close to ideal mixing conditions and low shear stress. Cell growth curves were prepared by culturing Escherichia coli and following its cell density in real-time. Our cell growth rate and maximum cell density were similar to those previously obtained in closely related systems. Therefore, the proposed bioreactors are an affordable alternative for batch and continuous cell growth studies rapidly and inexpensively.

Water and wastewater CFD and validation: are we losing the balance?

A literature screening on computational fluid dynamics (CFD) modelling in water treatment applications showed a vast range of validation ranging from no validation at all, over residence time distribution (RTD) and tracer testing, to velocity field, species concentration and, finally, turbulence properties measurements. The validation level also differs depending on process scale (laboratory, pilot, full) and type of system (rheology, single phase vs. multiphase). Given the fact that CFD is in more widespread use, a discussion on the extent and need of validation needs to be initiated. This paper serves as a discussion starter on the topic.

Polyhydroxybutyrate Production from Natural Gas in A Bubble Column Bioreactor: Simulation Using COMSOL

In this study, the simulation of microorganism ability for the production of poly-β-hydroxybutyrate (PHB) from natural gas (as a carbon source) was carried out. Based on the Taguchi algorithm, the optimum situations for PHB production from natural gas in the columnar bubble reactor with 30 cm length and 1.5 cm diameter at a temperature of 32 °C was evaluated. So, the volume ratio of air to methane of 50:50 was calculated. The simulation was carried out by COMSOL software with two-dimensional symmetric mode. Mass transfer, momentum, density-time, and density-place were investigated. The maximum production of biomass concentration reached was 1.63 g/L, which shows a 10% difference in contrast to the number of experimental results. Furthermore, the consequence of inlet gas rate on concentration and gas hold up was investigated Andres the simulation results were confirmed to experimental results with less than 20% error.

Computational fluid dynamics simulation in scaling-up of airlift photobioreactor for astaxanthin production

The unicellular green microalga Haematococcus pluvialis accumulates large amounts of the red ketocarotenoid astaxanthin. Aiming to cultivate these microalgae with high astaxanthin efficiency, cultivations were scaled-up from 1000 mL bottle to 2 L and 8 L airlift photobioreactor using volumetric power consumption rate (W/m³) as scale up strategy. After cultivations, computational fluid dynamics (CFD) simulation was used to investigate the flow patterns, mixing efficiency and gas holdup profile within the 2 L photobioreactor. At the end, astaxanthin content was enhanced with increasing the cultivation volume and highest astaxanthin amount of 49.39 ± 1.64 mg/g cell was obtained in 8 L photobioreactor. Hydrodynamic characteristics of photobioreactor was simulated and gas holdup showed difference between the riser and the downcomer regions. Velocity profiles of air and medium had higher values inside the draft tube than obtained in downcomer region. However liquid circulation was achieved from draft tube to the downcomer, mixing was not provided effectively considering the turbulence kinetic energy. For the further research, some developments about column configuration, sparger diameter may be necessary to enhance the mixing characteristics.

Computational fluid dynamics modeling of carbon dioxide capture from air using biocatalyst in an airlift reactor

In this work, a novel three-phase and three dimensional CFD model based on the Euler-Euler approach developed for modeling the hydrodynamic, mass transfer and CO₂ fixation using microalgae in an internal loop airlift reactor with internal sparger. The main objective of this work was to development of CFD codes in order to simulate the CO₂ biofixation process under different input gas velocity during 11 days of culture time and simulate the unsteady state mass transfer based on Surface-Renewal-Stretch (SRS) model. The CFD results were compared with the our previous experimental work and they showed good agreement with a margin of less than 10%. This paper illustrated the ability of the CFD in complex process simulation such as CO₂ biofixation in the airlift reactor and provided a useful basis for further study.

CFD Simulation on the Hydrodynamics in Gas-Liquid Airlift Reactor

Two-fluid model approach to simulate gas-liquid airlift reactors is widely implemented but have yet to reach a consensus on the closure model to account the gas-liquid interphase forces. Proper selection of a closure model is required in order to accurately capture the hydrodynamics in the complex of the two-phase system. Our work concerns the evaluation of the interfacial forces models (i. e. drag, lift and turbulent dispersion force) and their effects on local gas holdup and liquid velocity. A transient three-dimensional airlift reactor simulation was carried out using computational fluid dynamics by implementing the dispersed standardk-εturbulence model. Four drag models governed by spherical bubble, bubble deformation and Rayleigh-Taylor were being evaluated in our work. The significance on the inclusion of the lift model on predictive accuracy on the flow field was also studied as well. Whereas, two turbulent dispersion force models were selected to evaluate on their performance in improving the predictive accuracy of the local hydrodynamics. Results showed that the drag governed by Rayleigh-Taylor which accounts the bubble swarm effect had better predictions on the gas holdup in the downcomer and improved predictions in radial gas holdup. The inclusion of the lift model improved local gas holdup predictions at higher heights of the reactor and shifted the bubble plume towards the centre region of the riser. Meanwhile, the turbulent dispersion models improved the overall results of predicted local gas holdup with closer agreement obtained when the drift velocity model was considered in the simulation. The axial liquid velocity was well predicted for all cases. The consideration of the drag, lift and turbulent dispersion forces resulted in a closer agreement with experimental data.

Hydrodynamics and Mass Transfer Simulation in Airlift Bioreactor with Settler using Computational Fluid Dynamics

In this work, the effect of inlet-gas superficial velocity over the circulation liquid velocity, gas holdup and mass transfer, from an airlift bioreactor with settler were studied by Computational Fluid Dynamics (CFD) modeling and contrasted with experimental results. Multiphase mixture model and κ-ε turbulence model were used to describe the two phases gas-liquid flow pattern in airlift bioreactor. The hydrodynamic parameters such as liquid circulation velocity and gas holdup were computed by solving the governing equations of continuity, moment and turbulence transport using the finite volume method. Global mass transfer coefficient was evaluated through the Higbie’s penetration theory and the two-phase fluid dynamic theory. Comparison between our numerical data and experimental data previously reported in the literature was done. Numerical and experimental data were very close, and the differences found were discussed in terms of the limitations of this study.

Aerodynamic Drag Analysis of 3-DOF Flex-Gimbal GyroWheel System in the Sense of Ground Test

GyroWheel is an innovative device that combines the actuating capabilities of a control moment gyro with the rate sensing capabilities of a tuned rotor gyro by using a spinning flex-gimbal system. However, in the process of the ground test, the existence of aerodynamic disturbance is inevitable, which hinders the improvement of the specification performance and control accuracy. A vacuum tank test is a possible candidate but is sometimes unrealistic due to the substantial increase in costs and complexity involved. In this paper, the aerodynamic drag problem with respect to the 3-DOF flex-gimbal GyroWheel system is investigated by simulation analysis and experimental verification. Concretely, the angular momentum envelope property of the spinning rotor system is studied and its integral dynamical model is deduced based on the physical configuration of the GyroWheel system with an appropriately defined coordinate system. In the sequel, the fluid numerical model is established and the model geometries are checked with FLUENT software. According to the diversity and time-varying properties of the rotor motions in three-dimensions, the airflow field around the GyroWheel rotor is analyzed by simulation with respect to its varying angular velocity and tilt angle. The IPC-based experimental platform is introduced, and the properties of aerodynamic drag in the ground test condition are obtained through comparing the simulation with experimental results.

Effect of Scale on Hydrodynamics of Internal Gas-Lift Loop Reactor-Type Anaerobic Digester Using CFD

This work evaluates the ability of computational fluid dynamics (CFD) to simulate the flow and predict the hydrodynamics of internal gas-lift loop reactor (IGLR)-type anaerobic digester. In addition, it also analyzes if CFD can account for the effects of operating conditions, geometry as well as scale of the reactor. For this purpose, three-dimensional two-phase CFD simulations were performed using CFX for laboratory-scale and pilot-scale IGLR. The CFD predictions were evaluated against experimental data obtained from computer automated radioactive particle tracking (CARPT). The CFD predictions provided good qualitative but only reasonable quantitative comparison. After validation of CFD model, effect of gas flow rate, draft tube diameter, sparger geometry and reactor scale on flow pattern, liquid velocity and dead volume was investigated. Higher gas flow rates did not offer any significant advantage in increasing liquid circulation in the downcomer or decreasing the dead volume. Configuration with draft tube diameter half of tank diameter, equipped with cross sparger showed comparatively better liquid circulation than other configurations. For same superficial gas velocity, increasing the scale increases the magnitude of liquid velocity but fails to match the mixing intensity observed in laboratory scale. Different interphase forces, turbulence models and closures are also evaluated to improve the predictability of CFD models.

Modelling and Simulation of Gas–liquid Hydrodynamics in a Rectangular Air-lift Reactor

Computational Fluid Dynamics is a quite well established tool for carrying out realistic simulations of process apparatuses. However, as a difference from single phase systems, for multiphase systems the development of CFD models is still in progress. Among the two-phase systems, gas–liquid systems are characterised by an additional complexity level, related to the fact that bubble sizes are not known in advance, being rather the result of formation and breakage-coalescence dynamics and therefore of complex phenomena related to flow dynamics and interfacial effects. In the present work, Euler–Euler Reynolds-averaged flow simulations of an air-lift reactor are reported. All bubbles are assumed to share the same size, and a simplified approach is adopted for modelling inter-phase momentum exchange, that involves bubble terminal velocity as the sole parameter needed. Good agreement between simulation results and literature experimental data is found for all the gas flow rates simulated. This result implies that, despite the many simplifications that have to be adopted in order to make them viable, fully predictive CFD simulations of gas–liquid systems can give rise to reasonably accurate predictions of reactor fluid dynamics.