Influence of impeller type on mass transfer in fermentation vessels

Radial flow Rushton impellers were compared qualitatively with axial flow hydrofoil impellers (Maxflo T and A315) at the pilot scale. Six types of impellers were compared for qualitative differences in mass transfer. Measurements were conducted using three model systems: water, glycerol and Melojel (soluble starch). Power measurements were obtained using watt transducers, which although limited in accuracy and prone to interferences, were able to provide useful qualitative monitoring results. While there was little effect of impeller type on mass transfer as measured by the rapid pressure increase technique, significant qualitative differences were observed using the rapid temperature increase technique specifically for the Melojel and glycerol model systems. The Miller correlation, relating gassed-to-ungassed power, was used effectively to qualitatively evaluate the power drop upon gassing for both the model systems and a Streptomyces fermentation for the various impeller types. A high oxygen demand Streptomcyes fermentation then was conducted in fermenters possessing each type of impeller. Performance was not adequate with the A315 impellers pumping upwards and the small diameter Maxflo T impellers. Peak titers and profiles of the estimated apparent broth viscosity varied depending upon the impeller type. Mass transfer rates generally declined with higher viscosities when other fermentation operating conditions where held constant. Overall, values for OUR, k _L a, P _g /V _L and other calculated mass transfer and power input quantities for the A315 pumping upwards and undersized Maxflo T (D _T /D _I ?=?2.3) impellers were at the lower end of the range obtained for the larger Maxflo T (D _T /D _I ?=?1.8–2.0) and A315 impellers pumping downwards. Rushton impellers generally behaved qualitatively similar to hydrofoil impellers based on these calculated quantities.     

Mass transfer and liquid mixing in an airlift reactor with a net draft tube

Mass transfer and liquid mixing in an airlift reactor with a net draft tube were experimentally investigated. Four different column diameters were considered. The mass transfer was measured using the volumetric gas-liquid mass transfer coefficient which was determined by the dynamic method. The mass transfer coefficients in the airlift reactors with different column diameters were not always higher than those in the bubble columns. The liquid mixing was measured using mixing time which was determined by a pulse technique. Under the same superficial gas velocity, the mixing times of the airlift reactors with a net draft tube were always less than those of the bubble columns.List of Symbols C mol·dm^–3 bulk concentration of dissolved oxygen - C ₀ mol·dm^–3 initial concentration of dissolved oxygen - C _e mol·dm^–3 saturated concentration of dissolved oxygen - ¯C dimensionless dissolved oxygen concentration - D _c cm diameter of column - D _N cm diameter of the nozzle hole - D _T cm diameter of the net draft tube - H _L cm static liquid height - H _T cm height of the net draft tube - k _L a hr^–1 volumetric mass transfer coefficient - L _T cm length of the net draft tube - t _M sec mixing time of the liquid phase - t ₀ sec mixing time of the liquid phase in a bubble column - V _L dm³ volume of the liquid phase - U _g cm/s superficial air velocity     

The influence of impeller type in pilot scale xanthan fermentations

The rheological complexity of Xanthan fermentations presents an interesting problem from a mixing viewpoint, because the phenomena of poor bulk blending and low oxygen mass transfer rates inherent in highly viscous fermentations (and their consequences) can be systematically investigated, even at the pilot plant scale. This study in a 150 L fermentor compares the physical and biological performance of four pairs of impellers: a standard Rushton turbine, a large diameter Rushton turbine, a Prochem Maxflo T, and a Scaba 6SRGT. Accurate in-fermentor power measurements, essential for the comparison of impellers in relation to operating costs are also reported. It is demonstrated that the agitator performance in Xanthan fermentations is very specific and the choice of which impeller to use in bioreactors to obtain enhanced performance is dependant on the applied criterion. None of the criterion favored the use of the standard Rushton turbine, therefore suggesting that there are strong grounds for retrofitting these impellers with either large diameter impellers of similar design or with novel agitators. In addition, fluid dynamic modeling of cavern formation has clearly highlighted the importance of a well mixed and oxygenated region for providing the capacity for high microbial oxygen uptake rates which govern Xanthan productivity and quality. Copyright 1998 John Wiley & Sons, Inc.     

Application of fuzzy multiobjective optimization for self-sucking impellers in a bioreactor

For three types of self-sucking impellers (fourand six-pipe and disk impellers) mixing power, initial point, amount of gas leaving the impeller and mass transfer coefficient were determined experimentally. Investigations were performed for two systems: water and biomass solution.From the point of view of a minimum mixing power and maximum mass transfer coefficient the best impeller has been chosen. Fuzzy multiobjective optimization for determination of optimum operating conditions is proposed.List of Symbols c concentration of oxygen - D tank diameter - d impeller diameter - g acceleration of gravity - H height of liquid in the tank - H height of liquid above impeller, H=H-y - k consistency coefficient - k _L a volumetric mass transfer coefficient - N rotational speed of impeller - n flow behaviour index - P mixing power for pure liquid - P _G mixing power for aerated liquid - V _G volumetric air flow rate - y distance of impeller from the tank bottom - v _a apparent kinematic viscosity of liquid - density of liquid - time - gas hold-up - Eu=P/N ³ d ⁵ or Eu_G=P _G /N ³ d ⁵ Euler Number for non-gassed or aerated liquid - Fr=N ² d/g Froude Number - Fr^*=N ² d ² /g(H -y) modified Froude Number - K_G=V _G /N d ³ gas flow number - Re=N d ² /v _a Reynolds Number - Sh=k _K a/(g ² /v _a )^1/3 Sherwood Number     

A comprehensive comparison of mixing, mass transfer, Chinese hamster ovary cell growth, and antibody production using Rushton turbine and marine impellers

Large scale production of monoclonal antibodies has been accomplished using bioreactors with different length to diameter ratios, and diverse impeller and sparger designs. The differences in these physical attributes often result in dissimilar mass transfer, mechanical stresses due to turbulence and mixing inside the bioreactor that may lead to disparities in cell growth and antibody production. A rational analysis of impeller design parameters on cell growth, protein expression levels and subsequent antibody production is needed to understand such differences. The purpose of this study was to examine the impact of Rushton turbine and marine impeller designs on Chinese hamster ovary (CHO) cell growth and metabolism, and antibody production and quality. Experiments to evaluate mass transfer and mixing characteristics were conducted to determine if the nutrient requirements of the culture would be met. The analysis of mixing times indicated significant differences between marine and Rushton turbine impellers at the same power input per unit volume of liquid (P/V). However, no significant differences were observed between the two impellers at constant P/V with respect to oxygen and carbon dioxide mass transfer properties. Experiments were conducted with CHO cells to determine the impact of different flow patterns arising from the use of different impellers on cell growth, metabolism and antibody production. The analysis of cell culture data did not indicate any significant differences in any of the measured or calculated variables between marine and Rushton turbine impellers. More importantly, this study was able to demonstrate that the quality of the antibody was not altered with a change in the impeller geometry.     

Performance intensification of a stirred bioreactor for fermentative biohydrogen production

In this study, the biohydrogen (bioH₂) production of a microbial consortium was optimized by adjusting the type and configuration of two impellers, the mixing regimen and the mass transfer process (K_La coefficients). A continuous stirred-tank reactor (CSTR) system, with a nonstandard geometry, was characterized. Two different mixing configurations with either predominant axial (PB4 impeller) or radial pumping (Rushton impeller) were assessed and four different impeller configurations to produce bioH₂. The best configuration for an adequate mixing time was determined by an ANOVA analysis. A response surface methodology was also used to fully elucidate the optimal configuration. When the PB4 impellers were placed in best configuration, c/Dt?=?0.5, s/Di?=?1, the maximum bioH₂ productivity obtained was 440?mL?L^?1?hr^?1, with a bioH₂ molar yield of 1.8. The second best configuration obtained with the PB4 impellers presented a bioH₂ productivity of 407.94?mL?L^?1?hr^?1. The configurations based on Rushton impellers showed a lower bioH₂ productivity and bioH₂ molar yield of 177.065?mL?L^?1?hr^?1 and 0.71, respectively. The experiments with axial impellers (PB4) showed the lowest K_La coefficient and the highest bioH₂ production, suggesting that mixing is more important than K_La for the enhanced production of bioH_2.     

Strain selection,medium development and scale-up of toyocamycin production by streptomyces chrestomyceticus

The batch productivity (Q _TM) of the production of the nucleoside antibiotic toyocamycin (TM) by Streptomyces chrestomyceticus was increased ten-fold by selection of a UV generated mutant, optimization of pH, increasing incubation temperature from 28 °C to 36 °C, and addition of soy oil. Initial high oxygen transfer rates stimulated Q _TM maxima two-fold. Antibiotic production by the mutant strain, U190, however, appeared more shear sensitive than the parent culture FCRF 341 with maximum antibiotic titer being inversely related to impellor tip velocity, T _v . For this reason, scale-up could not be done at constant P/V or constant volumetric oxygen transfer. Instead, programming of impeller speed was evaluated in order to maintain optimal impeller tip velocity during scale-up. It was found that a low constant T _v maintained in scale-up in geometrically similar vessels was most beneficial for duplication of optimal antibiotic productivity, Q _TM. Pilot fermentations (120 dm³ scale) were used to determine coefficients of Q _TM variation from oxygen uptake rate (OUR) and total CO₂ evolution data for monitoring of Q _TM variation during scale-up to the 12,000 dm³ scale. This technique allowed for on-line prediction of antibiotic titer and Q _TM from fermentor exhaust gas data.List of Symbols A scale constant - B shape constant - C location of maximum constant - D m impeller diameter (m) - H m liquid height (m) - OTR MmolO₂·(dm³)^–1min^–1 oxygen transfer rate - OUR MmolO₂·(dm³)^–1min^–1 oxygen uptake rate - PCV cm³ packed cell volume - P/V watts/dm³ volumetric power consumption - Q 1 · min^–1 corrected to standard conditions of temperature, pressure aeration rate - Q _TM g/(cm³ · h) or kg/(m³ · h) antibiotic productivity - T m tank diameter - T _mix s mixing time - T _v cm · s^–1 impeller tip velocity - TM g/cm³ Toyocamycin concentration - TNP Tricyclic nucleoside phosphate     

Studies with a multiple-rod mixing impeller

The performance of a multiple-rod mixing impeller was compared to that of conventional turbine impellers in viscous novobiocin beers. The advantages of the multiple-rod impeller were found to be: (1) the power requirement was independent of changes in apparent viscosity of the fermentation beer; and (2) it gave the same novobiocin yield and oxygen-availability rate at about one-half of the power required by turbines.     

Scale-up of stirring as foam disruption (SAFD) to industrial scale

Foam disruption by agitation—the stirring as foam disruption (SAFD) technique—was scaled up to pilot and production scale using Rushton turbines and an up-pumping hydrofoil impeller, the Scaba 3SHP1. The dominating mechanism behind SAFD—foam entrainment—was also demonstrated at production scale. The mechanistic model for SAFD defines a fictitious liquid velocity generated by the (upper) impeller near the dispersion surface, which is correlated with complete foam disruption. This model proved to be scalable, thus enabling the model to be used for the design of SAFD applications. Axial upward pumping impellers appeared to be more effective with respect to SAFD than Rushton turbines, as demonstrated by retrofitting a 12,000 l bioreactor, i.e. the triple Rushton configuration was compared with a mixed impeller configuration from Scaba with a 20% lower ungassed power draw. The retrofitted impeller configuration allowed 10% more broth without risking excessive foaming. In this way a substantial increase in the volumetric productivity of the bioreactor was achieved. Design recommendations for the application of SAFD are given in this paper. Using these recommendations for the design of a 30,000 l scale bioreactor, almost foamless Escherichia coli fermentations were realised. Electronic Publication     

Effect of the impeller-sparger configuration over Trichoderma harzianum growth in four-phases cultures under constant dissolved oxygen

Three impeller-sparger configurations were used to evaluate the effect of different hydrodynamic conditions over fungal growth in rheologically complex cultures of Trichoderma harzianum using castor oil as sole carbon source. Three spargers (ring, sintered and 5-orifice) in combination with a turbine impeller system "TIS" (two Rushton turbines) or a hybrid impeller system "HIS" (Rushton turbine and a marine propeller as lower and upper impellers) were used. Their performance was assessed in terms of the response towards disturbance (PID oxygen control settings) and oxygen mass transfer (k_La). To avoid oxygen limitations, all cultures were controlled at 10% DOT by gas blending. Top to bottom mixing, and hence bulk blending, was improved when the - axial flow - HIS was used, ensuring phase interaction and substrate (oil) circulation. The 5-orifice sparger in combination with the TIS configuration yielded the longest lag phase and lowest k_La due to poor bulk blending and to the low gas-liquid interfacial area developed. The highest k_La was achieved with the sintered sparger-HIS probably due to considerable interfacial bubble area enhancement. However, growth limitation occurred as consequence of poor substrate availability as a stable air-oil emulsion was formed at the top of the tank. The best compromise between bulk blending (phase interaction), oxygen transfer (k_La) and fungal growth (growth rate) was achieved with the ring sparger-HIS configuration.     

Heat transfer coefficients and two-phase dispersion properties in a stirred-tank fermentor

Experiments were performed in a pilot scale 0.30 m³ conventional stirred-tank fermentor using water, air/water, and air/K₂SO₄ solutions. Both single- and two-stage impeller systems were investigated. Overall and tank-side coefficients for heat transfer from a 0.012 m diameter coil were measured for a range of impeller speeds and superficial gas velocities. Power input, bubble size, and gas hold-up were also determined. An analysis of the experimental results indicates that previously published correlations for single-phase heat transfer in stirred tanks (of the type: Nu = C(Re)^α(Pr)^β) are not applicable for single- or multiimpeller gas/liquid systems. The introduction of air alters the mixing pattern significantly, affecting both average and local tank-side heat transfer coefficients. Power input and gas hold-up are suggested as the major correlating parameters for the determination of tank-side heat transfer coefficients.     

CFD simulation of mixing for high-solids anaerobic digestion

A computational fluid dynamics (CFD) model that simulates mechanical mixing for high-solids anaerobic digestion was developed. Numerical simulations of mixing manure slurry which exhibits non-Newtonian pseudo-plastic fluid behavior were performed for six designs: (i) one helical ribbon impeller; (ii) one anchor impeller; (iii) one curtain-type impeller; (iv) three counterflow (CF-2) impellers; (v) two modified high solidity (MHS 3/39°) impellers; and (vi) two pitched blade turbine impellers. The CFD model was validated against measurements for mixing a Herschel-Bulkley fluid by ribbon and anchor impellers. Based on mixing time with respect to mixing energy level, three impeller types (ribbon, CF-2, and MHS 3/39°) stand out when agitating highly viscous fluids, of these mixing with two MHS 3/39° impellers requires the lowest power input to homogenize the manure slurry. A comparison of digestion material demonstrates that the mixing energy varies with manure type and total solids concentration to obtain a given mixing time. Moreover, an in-depth discussion about the CFD strategy, the influences of flow regime and impeller type on mixing characteristics, and the intrinsic relation between mixing and flow field is included.     

Improved scale-up strategies of bioreactors

Effective scale-up is essential for successful bioprocessing. While it is desirable to keep as many operating parameters constant as possible during the scale-up, the number of constant parameters realizable is limited by the degrees of freedom in designing the large-scale operation. Scale-up of aerobic fermentations is often carried out on the basis of a constant oxygen transfer coefficient, k _L a, to ensure the same oxygen supply rate to support normal growth and metabolism of the desired high cell populations. In this paper, it is proposed to replace the scale-up criterion of constant k _L by a more direct and meaningful criterion of equal oxygen transfer rate at a predetermined value of dissolved oxygen concentration. This can be achieved by using different oxygen partial pressures in the influent gas streams for different scales of operation. One more degree of freedom, i.e., gas-phase oxygen partial pressure, is thus added to the process of scale-up. Accordingly, one more operating factor can be maintained constant during scale-up. It can be used to regulate the power consumption in large-scale fermentors for economical considerations or to describe the fluid mixing more precisely. Examples are given to show that the results of optimization achieved in the bench-scale study can be translated to the production-scale fermentor more successfully with only a small change in the gas-phase oxygen partial pressure employed in the bench-scale operation.List of Symbols a m²/m³ Specific gas/liquid interfacial area - C _L mole/m³ Dissolved oxygen concentration in bulk liquid phase - C ^* mole/m³ Equilibrium oxygen concentration at gas/liquid interface - D _i m Impeller diameter - D _T m Bioreactor diameter - H _L mole/m³ · atm Henry's-law constant - k _L m/s Liquid-phase mass transfer coefficient - N 1/s Impeller agitation speed - N _i Number of impellers - OTR mole/s · m³ Oxygen transfer rate per unit volume of the medium - P _g kW Power input in aerated fermentation - P _o kW Power input in non-gassed fermentation - p _g atm Gas-phase oxygen partial pressure - Q m³/s Volumetric gas flow rate - Re _i Impeller Reynolds number - T _Q Joule Torque applied to the mixer shaft - V m³ Liquid volume - v _s m/s Superficial gas velocity - kg/m · s Liquid viscosity - kg/m³ Liquid density     

Using CFD simulations and statistical analysis to correlate oxygen mass transfer coefficient to both geometrical parameters and operating conditions in a stirred-tank bioreactor

Optimization of a bioreactor design can be an especially challenging process. For instance, testing different bioreactor vessel geometries and different impeller and sparger types, locations, and dimensions can lead to an exceedingly large number of configurations and necessary experiments. Computational fluid dynamics (CFD), therefore, has been widely used to model multiphase flow in stirred-tank bioreactors to minimize the number of optimization experiments. In this study, a multiphase CFD model with population balance equations are used to model gas–liquid mixing, as well as gas bubble distribution, in a 50 L single-use bioreactor vessel. The vessel is the larger chamber in an early prototype of a multichamber bioreactor for mammalian cell culture. The model results are validated with oxygen mass transfer coefficient (k_La) measurements within the prototype. The validated model is projected to predict the effect of using ring or pipe spargers of different sizes and the effect of varying the impeller diameter on k_La. The simulations show that ring spargers result in a superior k_La compared to pipe spargers, with an optimum sparger-to-impeller diameter ratio of 0.8. In addition, larger impellers are shown to improve k_La. A correlation of k_La is presented as a function of both the reactor geometry (i.e., sparger-to-impeller diameter ratio and impeller-to-vessel diameter ratio) and operating conditions (i.e., Reynolds number and gas flow rate). The resulting correlation can be used to predict k_La in a bioreactor and to optimize its design, geometry, and operating conditions.     

Characterization of stirrers for screening studies of enzymatic biomass hydrolyses on a milliliter scale

The evaluation of mixing quality is an important factor for improving the geometry of stirred-tank reactors and impellers used in bioprocess engineering applications, such as the enzymatic hydrolysis of plant materials. Homogeneity depends on different factors, including the stirrer type and the reactor type (e.g., ratio of diameter/height, ratio of impeller tip diameter/reactor diameter) with or without baffles. This study compares two impellers for enzymatic hydrolysis of suspensions of biomass particles on a milliliter scale. Both impellers were derived from industrially relevant geometries, such as blade and grid stirrers, although the geometry of the second stirrer was slightly modified to an asymmetric shape. The stirrers were investigated with different stirrer–reactor configurations. This was done experimentally and with the aid of computational fluid dynamics. The flow field, mixing numbers, power characteristics and initial conversion rates of sugars were considered to compare the two stirrers. The simulated mixing numbers and power characteristics in baffled and unbaffled milliliter-scale reactors were found to be in good agreement with the measured mixing times and power consumption. The mixing numbers required to reach homogeneity were much higher for the symmetric impeller and remained at least twice as high as the mixing numbers required when using the asymmetric impeller. The highest initial sugar releases from milled corn stover suspensions were achieved with the asymmetric impeller shape. Regardless of the differences in the flow fields or mixing times, diverging enzymatic sugar releases could be confirmed for Newtonian media only.     

An energy cost minimizing strategy for fermentation dissolved oxygen control

A cost-minimizing mathematical model for on-line control of dissolved oxygen using agitation speed and aeration rate was developed. In pilot scale monensin fermentation using Streptomyces cinnamonensis, this algortihm provided stable control of dissolved oxygen at 40%, reducing energy usage 27.8%. The agitation and aeration profiles provided by the algorithm respresent the pathway of least energy cost for control at the desired dissolved oxygen level. Other observed advantages of bivariable control were reduction of foaming, evaporation, and gas holdup. Reduced maintenance of compressors and agitator motors could also be expected due to decreased load. Monensin productivity equivalent to fermentation with constant agitation and aeration was not obtained, however, with potency reduced 14.8% with the dissolved oxygen control strategy.List of Symbols A m² cross sectional area of fermentor - A ₁, A ₂, A ₃, A ₄ constants of polynomial fit to Calderbank's equations - BP N/m² gauge back pressure - C _ag $/W/s cost of electrical power - C _Q $/m³ cost of compressed air - CE mol/m³/s carbon dioxide evolution rate - D m impeller diameter - DO, DO _meas, DO _sp % dissolved oxyen saturation at any time, measured, and setpoint respectively - h m height of liquid in fermentor - H N/m²/mmol Henry's constant for oxygen in water - H _av average gas holdup in fermentor - k _L a, k _L a _meas, k _L k _sp s^–1 oxygen mass transfer coefficient at any time, measured, and setpoint respectively - N, N _sp s^–1 agitation speed at any time and setpoint respectively - N _a, N _{a, sp} aeration number at any time and setpoint respectively - N _i total number of impellers - N _p impeller power number - N _s number of impellers into which air is directly sparged - OU, OU _meas mol/m³/s Oxygen uptake rate at any time and measured respectively - P W ungassed agitation power - P _g, P _g,meas, P _g,sp W gassed agitation power at any time, measured, and set point respectively - Q, Q _meas, Q _sp m³/s aeration rate at any time, measured, and setpoint respectively - T K fermentation temperature - u _g m/s linear gas velocity - V m³ fermentation liquid volume - mole fraction of oxygen in fermentation off-gas - calculation constant - motor efficiency - $/s sum of agitation and aeration costs - kg/m³ liquid density     

Effect of Impeller Clearance on Flow Structure and Mixing in Bioreactor with Two‐Stage Impellers

The effect of impeller clearance on flow structure and mixing time was simulated using a commercial software package CFX 4.3 and was measured experimentally. The mixing time calculated by simulation exhibited good agreement with the experimental data. The trend of forming independent flow compartments by each impeller became stronger as the clearance between two impellers increased. The homogeneity in the bioreactor was affected mainly by flow exchange between the compartments by each impeller. The most efficient mixing occurred when the impeller clearance was in the range of 0.2–0.4 vessel diameter.     

Enhanced glucan formation of filamentous fungi by effective mixing,oxygen limitation and fed-batch processing

Summary Glucan formation ofSchizophyllum commune andSclerotium glucanicum were investigated. Process data obtained during batch cultivation are presented. Glucan release can be improved by oxygen limitation. Thus, growth and glucan release are influenced by oxygen in opposite ways. Possible pathways of this oxygen-dependent regulation are discussed. A draft-tube/propeller system, rushtonturbine-, fan- and helicon-ribbon-impeller as well as a fundaspi and intermig agitator were tested. The 4-bladed fan impeller withd ^*=0.64 yielded the best results, since effective bulk mixing is much more important than bubble break up (micromixing) with regard to this system. Fed-batch cultivation always resulted in higher rates of glucan formation than the batch process.     

Improved performance in γ-polyglutamic acid production by Bacillus subtilis LX on industrial scale by impeller retrofitting and its unstructured microbial growth kinetics model

Abstract

We conducted industrial scale γ-polyglutamic acid (γ-PGA) production by Bacillus subtilis (B. subtilis) LX and modeled its microbial growth kinetics based on a logistic regression. We found that the use of a three-layer impeller including a lower semicircular disc impeller and two-layers of six-wide-leaf impellers were able to both increase γ-PGA yields and decrease fermentation time as compared with two-layer Rushton impellers. Indeed, our results revealed that the optimal γ-PGA yield (20.67?±?2.19?g/L) was obtained after 40?hr in the impeller retrofitted fermenter, and this yield was 29.7% higher than that in Rushton impellers fixed fermenter. The microbial growth kinetics of B. subtilis LX in this system were established, and the model was consistent with the experimental data (R² = 0.924) suggesting that it was suitable for describing the microbial growth kinetics underlying γ-PGA production on an industrial scale. In addition, biomass yield (Y_x/s-glucose), γ-PGA yield (Y_p/s-glucose), γ-PGA yield (Y_{p/s-glutamate}), and the correlation between γ-PGA production and B. subtilis LX (Y_p/x) were found to be 0.043, 0.133, 0.743, and 3.090?g/g, respectively, in the impeller retrofitted fermenter, as compared with 0.036, 0.103, 0.629, and 2.819?g/g, respectively, in the two-layer Rushton impeller fermenter.     

kLa of stirred tank bioreactors revisited

By means of improved feedback control k_La measurements become possible at a precision and reproducibility that now allow a closer look at the influences of power input and aeration rate on the oxygen mass transfer. These measurements are performed online during running fermentations without a notable impact on the biochemical conversion processes. A closer inspection of the mass transfer during cultivations showed that at least the number of impellers influences mass transfer and mixing: On the laboratory scale, two hollow blade impellers clearly showed a larger k_La than the usually employed three impeller versions when operated at the same agitation power and aeration rate. Hollow blade impellers are preferable under most operational conditions because of their perfect gas handling capacity. Mixing time studies showed that these two impeller systems are also preferable with respect to mixing. Furthermore the widths of the baffle bars depict a significant influence on the k_La. All this clearly supports the fact that it is not only the integral power density that finally determines k_La.