Investigations on hydrodynamics and mass transfer in gas–liquid stirred reactor using computational fluid dynamics

Effect of Mass Transport by Convective Flow on the Distribution of Dissolved Carbon Monoxide in a Stirred Tank

The dissolved gas concentration in a stirred tank has significant importance in the chemical and biological processing industries as mass transfer from the injected gas to an aqueous solution must occur for the gas to be usable. As the solubility of the gas in the solution is low and there are no probes for measuring dissolved gas concentration, a volumetric mass transfer coefficient is selected as a criterion of design for the scale-up of stirred reactors. However, it is difficult to accurately predict the non-equilibrium state dissolved gas distribution using only the volumetric mass transfer coefficient. In this study, computational fluid dynamics (CFD)-based numerical analysis was conducted to systematically evaluated the effects of mass transport by convective flow on the distribution of dissolved carbon monoxide in a stirred tank. The dissolved carbon monoxide distribution and the volumetric mass transfer coefficient were compared at various rotational speeds of the impellers. At a rotational speed of 900 RPM, the Pearson correlation coefficient was about 0.52, which denotes a moderate correlation. In contrast, Pearson correlation coefficients less than 0.20 were obtained for speeds less than 700 RPM, indicating a weak correlation. By considering the dissolved carbon monoxide transport that occurs during convective flow in stirred tanks, we can provide more accurate information about the dissolved carbon monoxide distribution.

Mass Transfer Features of Wavy-Bottomed Cascade Photobioreactors

It has been suggested that the energy-efficient production of microalgae biomass can be more easily obtained in short light path photobioreactors that can be operated at high biomass concentration. On the downside, however, high biomass concentrations also require an efficient gas exchange rate to avoid metabolic growth limitation or inhibition. A cascade photobioreactor featuring a thin liquid layer flowing down a sloping, wavy-bottomed surface can be operated at a biomass concentration that is much higher compared to most usual open-type equipment. Liquid flow, upon investigation, proved to exhibit peculiar “local recirculation” hydrodynamics, potentially conducive to the mixing of superficial and deep zones of the photobioreactor. Mass transfer coefficient represents a useful parameter to optimize the performance of a microalgal photobioreactor and its scale-up. The aim of the present article is to discuss the experimental mass transfer features of this novel type of photobioreactor and highlight expected opportunities and issues entailed by different ways of installing and operating such novel types of photobioreactors.

Towards enhancement of gas-liquid mass transfer in bioelectrochemical systems: Validation of a robust CFD model

Mass transfer has been identified as a major bottleneck in gas fermentation and microbial conversion of carbon dioxide to chemicals. We present a pragmatic and validated Computational Fluid Dynamics (CFD) model for mass transfer in bioelectrochemical systems. Experiments were conducted to measure mixing times and mass transfer in a Duran bottle and an H-cell. An Eulerian-Eulerian framework with a simplified model for the bubble size distribution (BSD) was developed that utilized only one additional equation for the bubble number density while including the breakup and coalescence. Validations of the CFD model for mixing times showed that the predictions were within the confidence intervals of the measurements, verifying the model's capability in simulating the hydrodynamics. Further validations were performed using constant and varying bubble diameters for the mass transfer. The results showed the benefits of a simplified BSD model, as it yielded improvements of seven and four times in accuracy when assessed against the experimental data for the Duran bottle and H-cell, respectively. Modeling of the H-cell predicted that a lower stirring rate improves mass transfer compared with higher stirring rates, which is of great importance when designing microbial cultivation processes. The model offers a feasible framework for advanced modeling of gas fermentation and microbial electrosynthesis.

Production of entomopathogenic nematodes in submerged monoxenic culture: A review

Monoxenic liquid culture is the most suitable technology for scaling up to industrial production of entomopathogenic nematodes (EPNs); however, the variability of the yield production remains a current problem in the process. The aim of this study was to analyze the parameters and criteria for EPN production in liquid culture based on scientific and technological knowledge from the last two decades. While experimental research has permitted the yield production of Heterorhabditis bacteriophora (362 × 10³ infective juveniles [IJs]/ml) and Steinernema carpocapsae (252 × 10³  IJs/ml), simultaneously, theoretical approaches have contributed to the understanding of the culture process, based on biological parameters of the bacterium-nematode complex and hydrodynamic and rheological parameters of the complex gas-liquid-solid system. Under this interdisciplinary research approach, bioprocess and biosystem engineering can contribute to design the various control strategies of the process variables, increase the productivity, and reduce the variability that until now distinguishes the in vitro production of EPNs by the liquid culture.

Gas-Liquid Contactors' Aeration Capacities When Agitated by Rushton Turbines of Various Diameters

Mass transfer processes are one of the most important operations in chemical, biochemical, and food industries worldwide. In the processes that are controlled by the gas-liquid mass transfer rate, the volumetric mass transfer coefficient k _L a becomes a crucial quantity. The dataset was measured with the aim to create a correlation for k _L a prediction in a non-coalescent batch under the wide range of experimental conditions. The dynamic pressure method, which was reported as physically correct in the past, was chosen to be the method for experimental determination of k _L a. Our previous work targeted the k _L a dependencies in viscous and coalescent batches resulting in correlations that are viable for the broad range of process conditions. We reported that the best-fit correlation is based on the hydrodynamic parameter circumferential velocity of impeller blades in the case of non-coalescent liquids in the vessel equipped by single or multiple impellers at a constant D/T ratio (diameter of the impeller to the inner diameter of the tank). Now, we focus on the influence of various impeller diameters on transport characteristics (mainly k _L a) in a non-coalescent batch. The experiments are carried out in a multiple-impeller vessel equipped with Rushton turbines (of four diameters) and in both laboratory and pilot-plant scales. Various impeller frequencies and gas flow rates are used. We examine the suitability of the hydrodynamic description, which was reported in the past, to predict k _L a also when the D/T ratio changes. We show that the correlation based on the energy dissipation rate better fits the experimental data and predicts k _L a values more accurately in the case of varying D/T values. This correlation could be adopted in the design and scale-up of agitated devices operating with non-coalescent batches.

Beyond heuristics: CFD-based novel multiparameter scale-up for geometrically disparate bioreactors demonstrated at industrial 2kL-10kL scales

The timely delivery of the most up-to-date medicines and drug products is essential for patients throughout the world. Successful scaling of the bioreactors used within the biopharmaceutical industry plays a large part in the quality and time to market of these products. Scale and topology differences between vessels add a large degree of complication and uncertainty within the scaling process. Currently, this approach is primarily achieved through extensive experimentation and facile empirical correlations, which can be costly and time consuming while providing limited information. The work undertaken in the current study demonstrates a more robust and complete approach using computational fluid dynamics (CFD) to provide potent multiparameter scalability, which only requires geometric and material properties before a comprehensive and detailed solution can be generated. The CFD model output parameters that can be applied in the scale-up include mass transfer rates, mixing times, shear rates, gas hold-up values, and bubble residence times. The authors examined three bioreactors with variable geometries and were able to validate them based on single-phase and multiphase experiments. Furthermore, leveraging the resulting CFD output information enabled the authors to successfully scale-up from a known 2kL to a novel and disparate 5kL single-use bioreactor in the first attempted cell culture. This multiparameter scaling approach promises to ultimately lead to a reduction in the time to market providing patients with earlier access to the most groundbreaking medicines.

Enhancing nemadectin production by Streptomyces cyaneogriseus ssp. noncyanogenus through quantitative evaluation and optimization of dissolved oxygen and shear force

In this study, effects of oxygen supply and shear stress on nemadectin production by Streptomyces cyaneogriseus ssp. noncyanogenus (S. cyaneogriseus) fermentation were investigated in shake flasks and 5-L bioreactors. Results showed sufficient dissolved oxygen level was essential for cells growth and nemadectin biosynthesis, while strong shear stress had negative impacts on both cell growth and nemadectin synthesis. Furthermore, when a combined paddle type was applied in culturing S. cyaneogriseus, the nemadectin production was increased by 23.6%. The influence of different agitation rates and paddle types on volumetric oxygen transfers coefficient (K_La) and shear stress were quantitatively studied through computational fluid dynamics simulation (CFD). The results of CFD revealed that high K_La as well as low shear stress co-existed under the combined impeller configuration at 650rpm. This study is expected to be helpful to the scale-up of nemadectin fermentation and other stress-sensitive but high-oxygen-consumption filamentous microorganism.

Numerical analysis of momentum transfer processes in a mechanically agitated air – biophase – liquid system

The results of numerical computations concerning momentum transfer processes in an air – biophase – liquid system agitated in a bioreactor equipped with baffles and a Smith turbine (CD 6 impeller) are presented in this paper. The effect of sucrose concentration on the distributions of the velocity of the continuous phase, gas hold-up and the size of gas bubbles in the system was analysed. Simulation results were presented in the form of the contours of the analysed magnitudes. The effect of sucrose concentration on the averaged values (i.e. determined on the basis of local values) of gas hold-up and gas bubbles size was evaluated. The results of the numerical computations of gas hold-up were compared with our own experimental data.

CFD Simulation of Gas Dispersion in a Stirred Tank of Dual Rushton Turbines

3D 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.

High efficiency cell-recycle continuous sodium gluconate production by Aspergillus niger using on-line physiological parameters association analysis to regulate feed rate rationally

In this paper, a system of cell-recycle continuous fermentation for sodium gluconate (SG) production by Aspergillus niger (A. niger) was established. Based on initial continuous fermentation result (100.0h) with constant feed rate, an automatic feedback strategy to regulate feed rate using on-line physiological parameters (OUR and DO) was proposed and applied successfully for the first time in the improved continuous fermentation (240.5h). Due to less auxiliary time, highest SG production rate (31.05±0.29gL(-1)h(-1)) and highest yield (0.984±0.067molmol(-1)), overall SG production capacity (975.8±5.8gh(-1)) in 50-L fermentor of improved continuous fermentation increased more than 300.0% compared to that of batch fermentation. Improvement of mass transfer and dispersed mycelia morphology were the two major reasons responsible for the high SG production rate. This system had been successfully applied to industrial fermentation and SG production was greatly improved.

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.