Active volume of mean circulation for stirred tanks agitated with axial impellers

Investigation of Low-Frequency Phenomena within Flow Pattern in Standard Mixing Vessel Induced by Pitched Blade Impeller

An experimental study on the flow pattern dynamics in a standard mixing vessel with radial baffles filled with water and induced by a pitched blade impeller pumping downward is presented. Investigation is mainly focused on detection and analysis of quasi-periodical or periodical low-frequency phenomenon connected with time- and length-scales considerably exceeding the Blade Passage Frequency (hereinafter BPF) and common turbulent eddies. This phenomenon, which is expressed as large-scale mean-flow variations, is generally known as flow Macro-Instability (hereinafter MI). It could break-down just below the liquid surface, or it crashes to the liquid surface and causes its Macro-Swelling (hereinafter MS). Our investigation was based on classical two-dimensional (2D) Particle Image Velocimetry (hereinafter PIV) measurement within 3 selected vertical planes in the vessel and subsequent analysis of the velocity field. The dominant frequencies evaluated in the selected points and overall analysis of the quasi-periodical macro-flow pattern behavior is to be shown. Identification of the quasi-periodical substructures appeared within the flow pattern was performed using the Oscillation Pattern Decomposition (hereinafter OPD) method. Observation of the macro-flow patterns confirmed presence of the macro-flow structures detected within flow pattern at the identical mixing pilot plant setup by previous investigations of the MIs phenomenon, i.e., the primary circulation loop and strong impeller discharge jet located in the lower vessel segment and the strong ascending wall current at the baffle, which break-down below the surface very often. A further important contribution of the presented work is the investigation of both flow pattern within the baffles vicinity and in the middle of the sector far from the baffle, showing a significant difference. Low-frequency periodical (or quasi-periodical) behavior of the investigated macro-structures was qualitatively confirmed by the presented results and it was quantified using the velocity dominant frequencies evaluation, as noted below. This frequency analysis brings insight into the supposed and detected interconnections between dynamics of the adjacent flow structures. Detected different flow patterns within the main plane near the baffles and in the inclined plane reveal a strong influence of the baffle presence to the local vertical flow, especially within the upper part of the vessel. Quite a different flow pattern appears tangentially in front of and behind the baffle, where a wake is revealed, indicating significant influence of the baffle on the local tangential flow. The new findings represent a contribution to better understanding the physical phenomena behind the standard mixing process.

On the fluid dynamics of a laboratory scale single-use stirred bioreactor

The commercial success of mammalian cell-derived recombinant proteins has fostered an increase in demand for novel single-use bioreactor (SUB) systems that facilitate greater productivity, increased flexibility and reduced costs (Zhang et al., 2010). These systems exhibit fluid flow regimes unlike those encountered in traditional glass/stainless steel bioreactors because of the way in which they are designed. With such disparate hydrodynamic environments between SUBs currently on the market, traditional scale-up approaches applied to stirred tanks should be revised. One such SUB is the Mobius^® 3 L CellReady, which consists of an upward-pumping marine scoping impeller. This work represents the first experimental study of the flow within the CellReady using a Particle Image Velocimetry (PIV) approach, combined with a biological study into the impact of these fluid dynamic characteristics on cell culture performance. The PIV study was conducted within the actual vessel, rather than using a purpose-built mimic. PIV measurements conveyed a degree of fluid compartmentalisation resulting from the up-pumping impeller. Both impeller tip speed and fluid working volume had an impact upon the fluid velocities and spatial distribution of turbulence within the vessel. Cell cultures were conducted using the GS-CHO cell-line (Lonza) producing an IgG₄ antibody. Disparity in cellular growth and viability throughout the range of operating conditions used (80-350 rpm and 1-2.4 L working volume) was not substantial, although a significant reduction in recombinant protein productivity was found at 350 rpm and 1 L working volume (corresponding to the highest Reynolds number tested in this work). The study shows promise in the use of PIV to improve understanding of the hydrodynamic environment within individual SUBs and allows identification of the critical hydrodynamic parameters under the different flow regimes for compatibility and scalability across the range of bioreactor platforms.

Macro-instability: a chaotic flow component in stirred tanks

Chaotic features of the macro-instability (MI) of flow patterns in stirred tanks are studied in this paper. Datasets obtained by measuring the axial component of the fluid velocity and the tangential force affecting the baffles are used. Two geometrically identical, flat-bottomed cylindrical mixing tanks (diameter of 0.3m) stirred with either pitched blade turbine impellers or Rushton turbine impeller are used in the experiments, and water and aqueous glycerol solutions are used as the working liquids. First, the presence of the MI component in the data is examined by spectral analysis. Then, the MI components are identified in the data using the proper orthogonal decomposition (POD) technique. The attractors of the macro-instability are reconstructed using either the POD eigenmodes or a method of delays and finally the attractor invariants are evaluated. The dependence of the correlation dimension and maximum Lyapunov exponent on the vessel operational conditions is determined together with their distribution within the tank. No significant spatial variability of the correlation dimension value is observed. Its value is strongly influenced by impeller speed and by the vessel-impeller geometry. More profound spatial distribution is displayed by the maximum Lyapunov exponent taking distinctly positive values. These two invariants, therefore, can be used to locate distinctive regions with qualitatively different MI dynamics within the stirred tank.

Optical analysis of liquid mixing in a minibioreactor

A novel optical sensor was used to study mixing and mean circulation time in a model minibioreactor (12.5 mL stirred vessel, equipped with a paddle impeller). Rotational rates in the range of 10-1,000 rpm corresponding to Reynolds number between 14 and 1,350 were studied. Results suggest that depending on the impeller rotational speed, mixing times up to 214 +/- 87 s can be reproducibly achieved. The minibioreactor was operated in the transitional regime, and it was determined that the non-dimensional form for mixing time, NTheta(M) was linearly dependent on Reynolds number. A linear correlation between mean circulation time and the inverse of rotational speed was also determined. The mean circulation time dependence on rotational speed in the 12.5 mL stirred vessel is similar to those found in large-scale stirred vessels. These results suggest that mixing and circulation times found in large-scale reactors can be replicated in minibioreactors.

Multiple-impeller systems with a special emphasis on bioreactors: a critical review

The multiple-impeller agitated systems are compared with single-impeller agitated systems with a special focus on its applications for bioreactors. Correlations reported in the literature for gas phase hold-up, mass transfer coefficient and power consumption under gassed and ungassed conditions are compared and recommendations have been made regarding their suitability for design and scale-up of bioreactors. The multiple-impeller systems are found to be superior as compared to single-impeller systems in all the above mentioned aspects, except liquid mixing. For all kinds of reactors where the sole purpose is mass transfer, multiple-impeller systems are advantageous and there would be large savings on an industrial scale, especially for the bioreactors where the reaction periods are long and the power consumption cost could be a significant component to the overall production costs.