Applicability of a modified breakage and coalescence model based on the complete turbulence spectrum concept for CFD simulation of gas-liquid mass transfer in a stirred tank reactor

Integration Approaches to Model Bioreactor Hydrodynamics and Cellular Kinetics for Advancing Bioprocess Optimisation

Large-scale bioprocesses are increasing globally to cater to the larger market demands for biological products. As fermenter volumes increase, the efficiency of mixing decreases, and environmental gradients become more pronounced compared to smaller scales. Consequently, the cells experience gradients in process parameters, which in turn affects the efficiency and profitability of the process. Computational fluid dynamics (CFD) simulations are being widely embraced for their ability to simulate bioprocess performance, facilitate bioprocess upscaling, downsizing, and process optimisation. Recently, CFD approaches have been integrated with dynamic Cell reaction kinetic (CRK) modelling to generate valuable information about the cellular response to fluctuating hydrodynamic parameters inside large production processes. Such coupled approaches have the potential to facilitate informed decision-making in intelligent biomanufacturing, aligning with the principles of "Industry 4.0" concerning digitalisation and automation. In this review, we discuss the benefits of utilising integrated CFD-CRK models and the different approaches to integrating CFD-based bioreactor hydrodynamic models with cellular kinetic models. We also highlight the suitability of different coupling approaches for bioprocess modelling in the purview of associated computational loads.

Numerical modelling of surface aeration and N2O emission in biological water resource recovery

Biokinetic modelling of N2O production and emission has been extensively studied in the past fifteen years. In contrast, the physical-chemical hydrodynamics of activated sludge reactor design and operation, and their impact on N2O emission, is less well understood. This study addresses knowledge gaps related to the systematic identification and calibration of computational fluid dynamic (CFD) simulation models. Additionally, factors influencing reliable prediction of aeration and N2O emission in surface aerated oxidation ditch-type reactor types are evaluated. The calibrated model accurately predicts liquid sensor measurements obtained in the Lynetten Water Resource Recovery Facility (WRRF), Denmark. Results highlight the equal importance of design and operational boundary conditions, alongside biokinetic parameters, in predicting N2O emission. Insights into the limitations of calibrating gas mass-transfer processes in two-phase CFD models of surface aeration systems are evaluated.

Effects of geometric parameters on volumetric mass transfer coefficient of non-Newtonian fluids in stirred tanks

Scaling up stirred tanks is a significant challenge because of the research gaps between laboratory and industrial-scale setups. It is necessary to understand the effects of scale-up on the mass transfer in stirred tanks, and this requires meticulous experimental analysis. The present study investigates the effects of tank size and aspect ratio ( H L T ${H}_{L}}{T}$ ) on the volumetric mass transfer coefficients of shear-thinning fluids. The experiments were conducted in three stirred tanks of different sizes (laboratory and pilot scale) and geometries (standard and nonstandard). H L T ${H}_{L}}{T}$ was 1 for the standard tanks and 3.5 for the nonstandard stirred tanks. Three sizes of stirred tanks were used: 11 L with H L T ${H}_{L}}{T}$ of 1, 40 L with H L T ${H}_{L}}{T}$ of 3.5, and 47 L with H L T ${H}_{L}}{T}$ of 1. Impeller stirring speeds and gas flow rates were in the range of 800–900 rev min−1 and 8–10 L min−1, respectively. The volumetric mass transfer coefficient was estimated based on the dissolved oxygen concentration in the fluids, and the effects of rheology and operating conditions on the volumetric mass transfer coefficient were observed. The volumetric mass transfer coefficient decreased as tank size increased and increased with an increase in operating conditions, but these effects were also clearly influenced by fluid rheology. The impacts of scale-up and operating conditions on the volumetric mass transfer coefficient decreased as liquid viscosity increased.