CFD Modeling of a Stirred Anaerobic Digestion Tank for Evaluating Energy Consumption through Mixing

Full-cycle study on developing a novel structured micromixer and evaluating the nanoparticle products as mRNA delivery carriers

Achieving precise control of nanoparticle size while maintaining consistency and high uniformity is of paramount importance for improving the efficacy of nanoparticle-based therapies and minimizing potential side effects. Although microfluidic technologies are widely used for reliable nanoparticle synthesis, they face challenges in meeting critical homogeneity requirements, mainly due to imperfect mixing efficiency. Furthermore, channel clogging during continuous operation presents a significant obstacle in terms of quality control, as it progressively impedes the mixing behavior necessary for consistent nanoparticle production for therapeutic delivery and complicates the scaling-up process. This study entailed the development of a 3D-printed novel micromixer embedded with hemispherical baffle microstructures, a dual vortex mixer (DVM), which integrates Dean vortices to generate two symmetrical counter-rotating intensified secondary flows. The DVM with a relatively large mixer volume showed rapid mixing characteristics even at a flow rate of several mL min-1 and produced highly uniform lipids, liposomes, and polymer nanoparticles in a size range (50-130 nm) and polydispersity index (PDI) values below 0.15. For the evaluation of products, SARS-CoV-2 Spike mRNA-loaded lipid nanoparticles were examined to verify protein expression in vitro and in vivo using firefly luciferase (FLuc) mRNA. This showed that the performance of the system is comparable to that of a commercial toroidal mixer. Moreover, the vigorous in-situ dispersion of nanoparticles by harnessing the power of vortex physically minimizes the occurrence of aggregation, ensuring consistent production performance without internal clogging of a half-day operation and facilitating quality control of the nanoparticles at desired scales.

Integrating biokinetics with computational fluid dynamics for energy performance analysis in anaerobic digestion

Anaerobic digestion (AD) is an effective process for decomposing organic matter in wastewater treatment plants (WWTPs) where highly efficient digesters properly mix the sludge. To ensure a uniform substance distribution, a comprehensive modeling method is necessary. Computational fluid dynamics (CFD) helps in the modeling of AD tanks but few studies have focused on integrating hydrodynamics with biokinetics because of complex AD processes. The current study presents a new CFD platform for estimating the biokinetics of WWTPs to assess the energy performance of AD tanks. The presented method is validated by numerical and experimental studies, and facilitates a link between methane production and mixing energy consumption. The on-site settings of the recirculation mixing system in the studied WWTP was able to prepare a uniform mixture of the material. However, reducing mixing rate to decrease energy consumption did not lead to proper mixing quality.