Oxygen transfer and mixing in a tower cycling fermentor

Tower cycling fermentors for the production of single-cell protein from volatile substrates were studied. The mass transfer, mixing and circulation patterns, and residence time distribution (RTD) curves were investigated in these vessels. This study suggests that the tower cycling fermentors for volatile substrates fermentation may improve product yields and at the same time reduce the power consumption, thereby resulting in a significant increase in operating cost savings and capital profits. The results of this research further indicate a future potential for commercial scale tower cycling fermentors.     

Oxygen transfer to mixed cultures in tower systems

A modified dynamic method is introduced to determine the oxygen transfer coefficient, K_L a, in aerobic fermentation systems which are not mechanically agitated. The dissolved oxygen concentration is measured continuously following a step down or a step up in aeration rate. The response curve is analyzed to obtain the value of K_La Experiments were carried out at several different air flow rates using mixed culture in concurrent tower fermentors with motionless mixers. The effect of sieve trays and Koch motionless mixers on oxygen transfer was investigated using a 3 in. diameter column. The values of K_L aobtained at the bottom of each column were found to be higher than those obtained at the top. Comparison of the results showed that the values ofK_L a were higher when the Koch mixers were used than when the sieve trays were employed. The oxygen uptake rate by the organisms rX, is also calculated by using the K_L a values obtained. They compare favorably withthe experimentally measured values.     

Intensification of transfer processes in biotechnology and chemical engineering using static mixers. (Review)

A review of the intensification of moment, mass and heat transfer using an “unconventional” method, namely the application of static mixers, also known as “motionless mixers”, is presented in this paper. After the presentation of some structural types of static mixers, studies with particular emphasis on flow behaviour, pressure drop, mixing, mass and, heat transfer in the presence of static mixing devices, used in biotechnology and chemical engineering, were discussed. The suitability of static mixers to enhance the transfer process parameters was also justified by the low energy requirement, while the fluids might have different viscosities and because of this fact they could remove any mistakes made by the equipment. The article is not directed towards a comprehensive review, but it should serve as a landmark in future undertakings.     

Hydrodynamics in external-loop airlift bioreactors with static mixers

Liquid circulation superficial velocity and gas holdup behaviours were investigated in an external-loop airlift bioreactor of 0.170?m³ liquid volume in gas-induced and forced-circulation-loop operation modes, in the presence of static mixers made of corrugated stainless steel pieces, resulting in packets with the height-to-diameter ratio equal to unity and using non-Newtonian starch solutions as liquid phase. The static mixers were disposed in the riser in three blocks, each with three mixing packets, successively turned 90° to the adjacent mixing element. It was found that in the presence of static mixers and forced-loop operation mode, liquid circulation superficial velocity in the riser section was significantly diminished, while gas holdup increased in a great measure. It was considered that static mixers split the fluid into individual streams and break up the bubbles, resulting in small bubble sizes with a relative homogeneous bubble distribution over riser cross section. They act as supplementary resistances in liquid flow, reducing riser cross sectional area, equivalent with A _D /A _R area ratio diminishing.     

Modelling of concentration profiles in tower fermenter. The influence of the axial dispersion coefficient

The production of CO₂ in tower fermenters which can cause back mixing, and thereby reducing the efficiency of such fermenters has been modelled with respect to fermentation. It is confirmed that the effect is significant. The effect of variations in the kinetic parameters, the maximum specific growth rate and the biomass yield coefficient was found to be insignificant. A good correlation between experimental and calculated data was obtained.     

Enhancement of mass transfer characteristics and phenanthrene degradation in a two-phase partitioning bioreactor equipped with internal static mixers

Oxygen and substrate supply have always been considered physical constraints for the performance and operation of two-phase partitioning bioreactors (TPPB), widely used for the degradation of hydrophobic substrates. In this regard, the potential advantages of static mixers in upgrading the oxygen transfer and liquid-liquid dispersions in TPPB have been highlighted. In the present paper, the concomitant influence of static mixers on the gas-liquid mass transfer coefficient k _L a and on substrate bioavailability was examined in TPPB. The static method based on conventional forms was developed to estimate the oxygen volumetric mass transfer coefficient. Over a broad range of liquid and air flow rates, the presence of static mixers was found to significantly enhance k _L a relative to a mixer-free mode of operation. For identical conditions, static mixers improved the k _L a threefold. In the presence of external aeration supply, the boost in the k _L a was associated with an increase of 16% in the phenanthrene biodegradation rate due to bubble break up accomplished by the static mixers. On the other hand, static mixers were efficient in enhancing substrate bioavailability by improving the liquid-liquid interfacial area. This effect was reflected by a threefold increase in the degradation rate in the bioreactors with no external supply of air when equipped with static mixers.     

Improvement of mass transfer characteristics and productivities of inclined tubular photobioreactors by installation of internal static mixers

The feasibility of improving mass transfer characteristics of inclined tubular photobioreactors by installation of static mixers was investigated. The mass transfer characteristics of the tubular photobioreactor varied depending on the type (shape) and the number of static mixers. The volumetric oxygen transfer coefficient ( k(L)a) and gas hold up of the photobioreactor with internal static mixers were significantly higher than those of the photobioreactor without static mixers. The k(L)a and gas hold up increased with the number of static mixers but the mixing time became longer due to restricted liquid flow through the static mixers. By installing the static mixers, the liquid flow changed from plug flow to turbulent mixing so that cells were moved between the surface and bottom of the photobioreactor. In outdoor culture of Chlorella sorokiniana, the photobioreactor with static mixers gave higher biomass productivities irrespective of the standing biomass concentration and solar radiation. The effectiveness of the static mixers (average percentage increase in the productivities of the photobioreactor with static mixers over the productivities obtained without static mixers) was higher at higher standing biomass concentrations and on cloudy days (solar radiation below 6 MJ m(-2) day(-1)).     

Oxygen transfer in mechanically agitated aqueous systems containing dispersed hydrocarbon

The effect of dispersed n -dodecane or n -hexadecane on the air-to-aqueous phase overall volumetric oxygen transfer coefficient in a simulated (cell-free) stirred-tank fermentor is described. The oil volume fraction ranged from zero to 0.10; the ionic strength of the aqueous phases was varied from 0 to 0.45. The air-to-aqueous phase coefficients in both oil-free (K_La) and oil-bearing (K_La*) systems were evaluated from unsteady-state experiments using a membrane-covered probe to follow the aqueous phase dissolved oxygen tension. For all systems studied, K_La*/K_La was found to be independent of P/V and v_s for all practical purposes. However, for a particular aqueous phase and at a given P/V and v_s, the ratio K_La*K_La generally differed from unity. Depending on the combination of hydrocarbon type and volume fraction and the aqueous-phase ionic strength employed, the dispersed hydrocarbon may, in some cases, reduce the rate of oxygen transfer and in others enhance it relative to that of the corresponding oil-free gas–liquid dispersion. Enhancement of the air-to-aqueous transfer rate by such negative spreading coefficient hydrocarbons has not been reported previously.     

Oxygen mass transfer in a bubble column bioreactor containing lysed yeast suspensions

Summary Liquid-phase volumetric oxygen transfer coefficients were evaluated in a bubble column containing yeast suspensions, using the instationary oxygen absorption method and a polarographic oxygen electrode. The electrode time lag was found to be independent of both the system studied and the operating conditions. The volumetric oxygen mass transfer coefficients k _L a could be reasonably predicted by calculating k _L from the equation derived by Bhavaraju et al. or the empirical equation of Calderbank and Moo-Young and a from the experimental gas hold-up values.Nomenclature a Exponent in Eq.6 or specific gas-liquid interfacial area based on reactor volume m - b Exponent in Eq. 6 - C Constant in Eq 6 or oxygen concentration in the liquid phase g/ml - C ^* Equilibrium oxygen concentration g/ml - C ₀ Oxygen concentration in the liquid phase at t=0 g/ml - C _E Oxygen concentration as determined by the polarographic electrode g/ml - D _B Bubble equivalent diameter mm - D _l Oxygen diffusivity in the liquid phase m²/s - g Acceleration of gravity m/s² - K Consistency index Pasⁿ - K _L Liquid-phase mass transfer coefficient m/s - n Power law exponent - Pe _sw Peclet number based on bubble swarm velocity - S _C Schmidt number - Sh Sherwood number - i Time s - U _B Bubble rise velocity in infinite medium m/s - U _g Superficial air velocity based on column cross-sectional area m/s - U _sw Bubble swarm velocity defined by Eq.15 m/s - Y _MSW Mass transfer coeficient correction factor for mobile interfaces in pseudo-plastic fluids Eq. 7 - Y _MSW Mass transfer coefficient correction factor for immobile interface in pseudo-plastic fluids Eq. 8 Greek letters _l Density of liquid g/ml - _sus Density of unaerated suspension g/ml - _{wet cell} Density of yeast wet cells g/ml - _l Viscosity of the liquid Pas - _app Apparent viscosity of power law fluid Pas - _E Electrode time lag s - _l Time lag due to resistance of the gas-liquid interface s - _g Gas hold-up, volume fraction occupied by the gas phase - _l Liquid hold-up - _c Wet cell volume fraction     

Phases dispersion and oxygen transfer in a simulated fermentation broth containing castor oil and proteins

The sizes of air bubbles and castor oil drops were studied by image analysis as a function of the concentration of soluble protein (bovine serum albumin [BSA] and lipase, as model proteins) in a three-phase system using a simulated fermentation medium (aqueous salt solution, castor oil, and air). Small amounts of proteins (<0.02 g/L) caused an important decrease in oil drops and bubbles sizes, together with a pronounced decrease in surface tension. The extent and profiles of this decrease seem to be determined by the conformation of the protein at the interface. The kLa value increased considerably for increasing concentration (up to 0.02 g/L) of the two proteins but was very different (2-fold higher for the lipase) at the highest concentrations tested (0.5 g/L), a phenomenon that can be caused by the extent to which bubbles are trapped within oil drops.     

Oxygen transfer in liquids

In the laboratory-type airlift tower reactor oxygen transfer from air in tap water and/or polyacrylamide solutions (Neuperm WF) was studied. In order to characterize the system, volumetric coefficient of oxygen transfer was determined by the gassing-out method. Two arrangements of the airlift tower reactor were compared, namely the reactor with and without motionless mixer. In addition, mean relative gas holdup and gas power output were determined for both arrangements.     

Oxygen transfer to mycelial fermentation broths in an airlift fermentor

Oxygen transfer rates and gas holdups were measured in mycelial fermentation broths of Chaetomium cellulolyticum and Neurospora sitophila, each cultured in a 1300-L pilot-plant-scale airlift fermentor. These cultures exhibited highly non-Newtonian flow behavior coupled with a substantial decrease in oxygen transfer rates. The volumetric mass transfer coefficients in these cultures were found to be 65-70% lower than those in water. The data were compared with the available correlations obtained for simulated fermentation broths. In general, the data for C. cellulolyticum are in satisfactory agreement with the correlations for the model media but the data for N. sitophila are higher than that predicted by the correlations. Model media based correlations are found to be applicable to the fermentation processes if the culture medium does not possess a high yield stress.     

Dimensionless criteria for estimating oxygen transfer in aeration systems

The effect of power consumption on oxygen transfer efficiency has been evaluated for both surface and subsurface aeration systems. Two new dimensionless criteria (numbers) have been proposed for this purpose. They are termed the efficiency criterion or T(o) number and the power consumption effect criterion or Av number. The analysis presented in this article is based on data obtained on various full-scale aeration systems, and it shows that for each aerator there is an optimum power consumption at which maximum oxygen transfer efficiency results. The oxygen transfer efficiency has maximum values when the efficiency criterion (T(o) number) reaches an approximately constant value. The results have proven that when there are several aerators with identical diameters and the same rotational velocity but different geometrical shapes, the most efficient one will be (after having reached the maximum transfer efficiency) the one with the highest power consumption. For two aerators varying in diameter but with the same parameter as above (maximum transfer, equal rotational velocity), different efficiencies are obtained, the difference being a function of d(-0.5). The results of investigating subsurface aeration systems show that the efficiency of decreased.     

Effect of additives on mass transfer in turbine aeration

Mass transfer coefficients and interfacial areas were determined for the aeration of aqueous solutions in a turbine agitated vessel. The mass transfer coefficients measured for water without additive and for sodium chloride solutions matched very well to measurements in the literature for air bubbles of the same diameter in free rise. Thus the only effect of agitation was to determine the bubble size which then in turn set the coefficient. Two surface active agents were studied: sodium dodecyl sulfate and Dow Corning Antifoam C. The rate of mass transfer increased with the former additive but decreased with the latter; however, the mass transfer coefficient was the exact same function of bubble diameter in both cases and the different rates are attributed to the quite different effects on interfacial area.     

Oxygen transfer in an airlift reactor with multiple net draft tubes

A pilot scale airlift reactor with multiple net draft tubes was developed to improve oxygen transfer in the reactor. The reactor was 0.29 m in diameter and 2 m height. A steadystate sulfite oxidation method was applied to determine an overall volumetric mass transfer coefficient. Oxygen transfer of the proposed airlift reactor can be 60–100% higher than that of bubble columns under the same operating conditions.List of Symbols C ^* mol·dm^–3 saturated concentration of dissolved oxygen - C _L mol·dm^–3 bulk concentration of dissolved oxygen - G mol/min nitrogen flow rate - k _L a hr^–1 the volumetric gas-liquid mass transfer coefficient - Mo ₂ g/mol molecular weight of oxygen - OTR g/min the oxygen transfer rate - U _g cm/s superficial air velocity - V _L dm³ volume of the liquid phase - _in oxygen mole ratio in the inlet gas - _out oxygen mole ratio in the outlet gas     

Stochastic modelling of axial dispersion in external-loop airlift bioreactors

The paper presents a model of the motion of a particle subjected to several transport processes in connection with mixing in two phase flow. A residence time distribution technique coupled with a one-dimensional dispersion model was used to obtain the axial dispersion coefficient in the liquid phase, D_ax. The proposed model of D_ax for an external-loop airlift bioreactor is based on the stochastic analysis of the two-phase flow in a cocurrent bubble column and modified for the specific flow in the airlift reactor. The model takes into account the riser gas superficial velocity, the riser liquid superficial velocity, the Sauter bubble diameter, the riser gas hold-up, the downcomer-to-riser cross sectional area ratio. The proposed model can be applied with an average error of ᆨ.     

Oxygen transfer modeling and simulations for an industrial continuous airlift fermentor

This article deals with the modeling of the oxygen transfer in an industrial airlift fermentor used for lactic yeast production on whey substrates. The purpose of this study was to improve the understanding of the interactions among the various parameters that govern the oxygen transfer phenomena in this type of fermentor. The reliability of the proposed model is demonstrated. The results of the investigations have been put into practice on the industrial scale and have contributed to monitor better the fermentation process. The model was also used to develop new ways of industrial fermentor design.     

Oxygen transfer in slurry bioreactors

The oxygen transfer in bioreactors with slurries having a yield stress was investigated. The volumetric mass transfer coefficients in a 40-L bubble column with simulated fermentation broths, the Theological properties of which were represented by the Casson model, were measured. Experimental data were compared with a theoretical correlation developed on the basis of a combination of Higbie's penetration theory and Kolmogoroff's theory of isotropic turbulence. Comparisons between the proposed correlation and data for the simulated broths show good agreement. The mass transfer data for actual mycelial fermentation broths reported previously by the authors were re-examined. Their Theological data was correlated by the Bingham plastic model. The oxygen transfer rate data in the mycelial fermentation broths fit the predictions of the proposed theoretical correlation.