Hydrodynamics and Mass Transfer Analysis in BioFlow® Bioreactor Systems

Biotechnological processes involving the presence of microorganisms are realized by using various types of stirred tanks or laboratory-scale dual-impeller commercial bioreactor. Hydrodynamics and mass transfer rate are crucial parameters describing the functionality and efficiency of bioreactors. Both parameters strictly depend on mixing applied during bioprocesses conducted in bioreactors. Establishing optimum hydrodynamics conditions for the realized process with microorganisms maximizes the yield of desired products. Therefore, our main objective was to analyze and define the main operational hydrodynamic parameters (including flow field, power consumption, mixing time, and mixing energy) and mass transfer process (in this case, gas–liquid transfer) of two different commercial bioreactors (BioFlo® 115 and BioFlo® 415). The obtained results are allowed using mathematical relationships to describe the analyzed processes that can be used to predict the mixing process and mass transfer ratio in BioFlo® bioreactors. The proposed correlations may be applied for the design of a scaled-up or scaled-down bioreactors.

Mathematical Modeling of Hydrodynamics in Bioreactor by Means of CFD-Based Compartment Model

This study presents the procedure of deriving a compartmental model (CM) based on an analysis obtained from the computational fluid dynamics (CFD) model of a bioreactor. The CM is composed of two parts, a structural (that takes into account the architecture of the mathematical model), and a parametric part (which contains the extrinsic parameters of the model). The CM is composed of the branches containing the set of perfectly mixed continuous stirred-tank reactors (CSTRs) in a configuration that matches the bioreactor’s flow patterns. Therefore, this work’s main objective was to develop a mathematical model that incorporated the flow field obtained by CFD technique. The proposed mathematical model was validated by means of the experimental data in the form of the residence time distribution (RTD) measurements.

Enzymatic hydrolysis at high dry matter content: The influence of the substrates' physical properties and of loading strategies on mixing and energetic consumption

The present work investigates the impact of the physical properties and loading strategies of wheat straw and miscanthus on enzymatic hydrolysis at high DM concentration. Three parameters have been chosen to evaluate the enzymatic hydrolysis performance: (i) the mixing time, (ii) the energetic mixing consumption and (iii) the glucose concentration. It was demonstrated that the hydrolysis of miscanthus is easy to perform and has low viscosity. On the contrary, the higher porosity grade of wheat straw than miscanthus (73% against 52%) contributed to have a very high viscosity at 20% w/w DM. The development of a fed-batch strategy allowed the reduction of viscosity inducing the energetic consumption lowering from 30 kJ to 10 kJ. It has been also proven that the miscanthus addition in wheat straw achieved to decrease mixing energy consumption at 5-8 kJ, when it represented more than 30% of the total mass of the reaction medium.

Radiotracer investigation on the measurement of residence time distribution in an ethyl acetate reactor system with a large recycle ratio

A radiotracer investigation was carried out on the measurement of residence time distribution (RTD) of process fluid in an industrial-scale ethyl acetate reactor system, which consists of two independent reactors with recirculation and connected in series with each other. Bromine-82 as ammonium bromide was used as the radiotracer for the RTD experiments at different operating conditions. The individual reactors and the overall reactor system were modelled using physically representative phenomenological models comprising of continuously stirred tank reactors (CSTRs). The results showed that the recirculation rate considerably affected the flow mixing behaviour and mean residence time of the process fluid in the reactor system. The results also showed that there was bypassing of the fluid in the first reactor that ranged from 12% to 22% and 40% dead volume at different operating conditions, whereas the second reactor behaved closely as an ideal CSTR. The results of the investigation can be used to optimise the process parameters and design new improved reactor systems for the production of ethyl acetate.

Radiotracer technology in mixing processes for industrial applications

Many problems associated with the mixing process remain unsolved and result in poor mixing performance. The residence time distribution (RTD) and the mixing time are the most important parameters that determine the homogenisation that is achieved in the mixing vessel and are discussed in detail in this paper. In addition, this paper reviews the current problems associated with conventional tracers, mathematical models, and computational fluid dynamics simulations involved in radiotracer experiments and hybrid of radiotracer.