A new simple approach for the scale-up of aerated stirred tanks

Substantial gradient mitigation in simulated large-scale bioreactors by optimally placed multiple feed points

The performance of large-scale stirred tank and bubble column bioreactors is often hindered by insufficient macromixing of feeds, leading to heterogeneities in pH, substrate, and oxygen, which complicates process scale-up. Appropriate feed placement or the use of multiple feed points could improve mixing. Here, theoretically optimal placement of feed points was derived using one-dimensional diffusion equations. The utility of optimal multipoint feeds was evaluated with mixing, pH control, and bioreaction simulations using three-dimensional compartment models of four industrially relevant bioreactors with working volumes ranging from 8 to 237 m³ . Dividing the vessel axially in equal-sized compartments and locating a feed point or multiple feed points symmetrically in each compartment reduced the mixing time substantially by more than a minute and mitigated gradients of pH, substrate, and oxygen. Performance of the large-scale bioreactors was consequently restored to ideal, homogeneous reactor performance: oxygen consumption and biomass yield were recovered and the phenotypical heterogeneity of the biomass population was diminished.

Transitioning from a lab-scale PLGA microparticle formulation to pilot-scale manufacturing

The complexity of scale-up manufacturing of PLGA microparticles creates a significant challenge when transitioning from benchtop-scale formulation development into larger clinical scale batches. Minor changes in the initial formulation composition (e.g., PLGA molecular weight, solvent type, and drug concentration) and processing parameters (e.g., extraction kinetics and drying condition) during scale-up production can result in significantly different performance of the prepared microparticles. The objectives of the present study were to highlight the in vitro and in vivo performance of a candidate benchtop-scale batch created with a rotor-stator mixer, transitioned into an in-line manufacturing process at ~15× scale of a long-acting naltrexone formulation. Physicochemical properties (such as drug loading, residual benzyl alcohol content, and morphology) as well as the in vitro release characteristics of the prepared naltrexone microparticles between the benchtop-scale and in-line process pilot-scale were determined. The pharmacokinetics of the naltrexone microspheres were investigated using the rat model. The results demonstrate that while the morphologies of the particles were different from a visual assessment and slight differences were observed in the in vitro release profiles, the in vivo pharmacokinetics illustrate similar kinetics. Our study shows that scale-up production having the same drug release kinetics can be made by controlling the formulation and processing parameters.

Gas Dispersion in Non-Newtonian Fluids with Mechanically Agitated Systems: A Review

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.

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.

The effect of mixing and free-floating carrier media on bioaerosol release from wastewater: a multiscale investigation with Bacillus globigii

Aeration tanks in wastewater treatment plants (WWTPs) are significant sources of bioaerosols, which contain microbial contaminants and can travel miles from the site of origin, risking the health of operators and the general public. One potential mitigation strategy is to apply free-floating carrier media (FFCM) to suppress bioaerosol emission. This article presents a multiscale study on the effects of mixing and FFCM on bioaerosol release using Bacillus globigii spores in well-defined liquid media. Bioaerosol release, defined as percentage of spores aerosolized during a 30 minute sampling period, ranged from 6.09 × 10-7% to 0.057%, depending upon the mixing mode and intensity. Bioaerosol release increased with the intensity of aeration (rotating speed in mechanical agitation and aeration rate in diffused aeration). A surface layer of polystyrene beads reduced bioaerosol released by >92% in the bench-scale studies and >74% in the pilot-scale study. This study discovered strong correlations (R2 > 0.82) between bioaerosol release and superficial gas velocity, Froude number, and volumetric gas flow per unit liquid volume per minute. The Reynolds number was found to be poorly correlated with bioaerosol release (R2 < 0.5). This study is a significant step toward the development of predictive models for full scale systems.

Comparative investigation of fine bubble and macrobubble aeration on gas utility and biotransformation productivity

The sufficient provision of oxygen is mandatory for enzymatic oxidations in aqueous solution, however, in process optimization this still is a bottleneck that cannot be overcome with the established methods of macrobubble aeration. Providing higher mass transfer performance through microbubble aerators, inefficient aeration can be overcome or improved. Investigating the mass transport performance in a model protein solution, the microbubble aeration results in higher k_L a values related to the applied airstream in comparison with macrobubble aeration. Comparing the aerators at identical k_L a of 160 and 60 1/h, the microbubble aeration is resulting in 25 and 44 times enhanced gas utility compared with aeration with macrobubbles. To prove the feasibility of microbubbles in biocatalysis, the productivity of a glucose oxidase catalyzed biotransformation is compared with macrobubble aeration as well as the gas-saving potential. In contrast to the expectation that the same productivities are achieved at identically applied k_L a, microbubble aeration increased the gluconic acid productivity by 32% and resulted in 41.6 times higher oxygen utilization. The observed advantages of microbubble aeration are based on the large volume-specific interfacial area combined with a prolonged residence time, which results in a high mass transfer performance, less enzyme deactivation by foam formation, and reduced gas consumption. This makes microbubble aerators favorable for application in biocatalysis.

Biotransformation of cladribine by a nanostabilized extremophilic biocatalyst

Cladribine (2-chloro-2'-deoxy-β-d-adenosine) is a 2'-deoxyadenosine analogue, approved by the FDA for the treatment of hairy cell leukemia and more recently has been proved for therapeutic against many autoimmune diseases as multiple sclerosis. The biosynthesis of this compound using Thermomonospora alba CECT 3324 as biocatalyst is herein reported. This thermophilic microorganism was successfully entrapped in polyacrylamide gel supplemented with nanoclays such as bentonite. The immobilized biocatalyst (T. alba-Ac-Bent 1.00 %), was able to biosynthesize cladribine with a conversion of 89 % in 1 h of reaction and retains its activity for more than 270 reuses without significantly activity loss, showing better operational stability and mechanical properties than the natural matrix. A microscale assay using the developed system, could allow the production of at least 181 mg of cladribine in successive bioprocesses.

Biotransformation of cladribine using a stabilized biocatalyst in calcium alginate beads

Cladribine is a nucleoside analogue widely used in the pharmaceutical industry for the treatment of several neoplasms, including hairy-cell leukemia among others. This compound has also shown efficacy in the treatment of autoimmune diseases such as rheumatoid arthritis and multiple sclerosis. In this work, a green bioprocess for cladribine biosynthesis using immobilized Arthrobacter oxydans was developed. The microorganism was stabilized by entrapment immobilization in the natural matrix alginate. Different reaction parameters were optimized obtaining a biocatalyst able to achieve cladribine bioconversion values close to 85% after 1 hr, the shortest reaction times reported so far. The developed bioprocess was successfully scaled-up reaching a productivity of 138 mg L^-1 hr^-1 . Also, the biocatalyst was stable for 5 months in storage and in 96 hr at operational conditions.

Numerical Simulation of Biomass Growth in OKTOP®9000 Reactor at Industrial Scale

Computational fluid dynamics is a powerful method for scale-up of reactors although it is still challenging to fully embrace hydrodynamics and biological complexities. In this article, an aerobic fermentation of Pichia pastoris cells is modeled in a batch OKTOP®9000 reactor. The 800 m³ industrial scale reactor is equipped with a radial impeller, designed by Outotec Oy for gas dispersion in the draft tube reactor. Measured N_p of the impeller is used in hydrodynamics validation. The resolved energy dissipation rate is compensated, and its influence on mass transfer is analyzed and discussed. Gas–liquid drag force is modified to simulate effects of liquid turbulence and bubble swarms. Resolved steady state multiphase hydrodynamics is used to simulate the fermentation process. Temporal evolution of species concentrations is compared to experimental data measured in a small copy of the reactor at lab scale (14 L). The effect of oxygenation on the P. pastoris cells cultivation is considered.

Optical Approach for Measuring Oxygen Mass Transfer in Stirred Tank Bioreactors

Bioreactor engineering allows modeling the conditions of real life biological processes. Particularly, oxygen represents one of the most important factors for life, and the understanding and control of its mass transfer in bioreactors is one of the most challenging problems in the industry. The aim of this study was to develop an optical approach for measuring the oxygen mass transfer coefficient (kLa). An assembly was constructed for this purpose, consisting of a stirred tank bioreactor, a high-intensity light source, a luminometer and a digital camera. Air flux supply and stirring velocity of the bioreactor were tested over a range of thirty-five values. The air bubbles generated were counted and their diameters were measured from photographs. The luminometer measured light obstruction due to bubbles. A polarography electrode sensor measured the dissolved oxygen in water to correlate it with the optical approach. The results showed a close correlation between kLa and light obstructed due to bubbles of air. The bubble diameter and holdup results suggest that the size of the bubbles decreases and becomes more homogeneous as stirring speed increases. A multivariable linear model for kLa as a function of the measured light obstruction and air flux injection was constructed. A strong correlation between this model and results was obtained. This approach avoids the need for chemical sensors for sensing systems, with a noninvasive and nondestructive methodology to determine the kLa for dilute solutions. This technique could be developed to evaluate a scaled-up bioreactor before running a bioprocess.