Power consumption of three impeller combinations in mixing Xanthan fermentation broths

Xanthan gum fermentation represents a good model for the study of the mixing of rheologically complex culture broths. Most of the previous work on power consumption dealt with ‘standard’, single impellers and used model fluids to simulate xanthan broths. This work describes the characterization of three dual-impeller combinations (D/T = 0·53) for the mixing of dehydrated—reconstituted fermentation broths of Xanthomonas campestris that had matched rheology to the actual broths. The bottom impeller was a Rushton turbine (RT) and the top impeller was another RT, a 45° pitched blade turbine (PT) or an A-310 Lightnin mixer (A310). The experiments were carried out in a tank of 0·0094 m³ working volume equipped with an air bearing dynamometer. The power was measured in a wide range of xanthan concentrations (5–40 kg m⁻³) in aerated (0·25, 0·5 and 1·0 vvm) and unaerated conditions. Unaerated power number (Po) vs. Reynolds number (Re) curves showed similar trends for the three combinations. Exponents close to −1 were obtained in the laminar region. A minimum in Po (Po_min) occurred at Re = 30–40, then increasing to a plateau value which was evident at Re> 200. In the transition region Po_min values were 4·3 (RT and RT), 3·6 (RT and PT) and 2·4 (RT and A310). The aerated power data for (RT and PT) and (RT and A-310) showed higher torque instabilities than the dual RT combinations at higher xanthan concentrations. The higher the xanthan concentrations, the higher the drop in power and the less important the effect of the aeration rate. Among the combinations tested, when using Rushton turbines, the well-mixed ‘cavern’ reached the tank wall (i.e., fluid motion was observed) at the lowest volumetric power input. High     

Evaluation of mixing effect and shear stress of different impeller combinations on nemadectin fermentation

Mass transfer and shear force have significant effects on nemadectin production by Streptomyces cyaneogriseus ssp. noncyanogenus. They are always the conflict-ridden problems in nemadectin fermentation process. In this study, the flow field characteristics under different impeller combinations were quantitatively evaluated in 5 L stirred-tank bioreactor through the laser particle image velocimetry (PIV) system. Results demonstrated that the radial-axial impeller combinations with the time average velocity at 0.38-0.54 U_tip, the turbulent kinetic energy dissipation rate at 6.4–10.6 ε/N³D², and the shear stress rate was 40-150 s⁻¹, were more conductive to cell growth, nemadectin biosynthesis, cell’s activity, respiratory metabolism than other combinations. The highest nemadectin yield was evaluated up to 1543.3 ± 18.5 μg/mL, which was 31.68 % higher than that of the radial flow impeller combinations. This study provided the important guideline for the selection impeller combinations’ on large-scale nemadectin production.     

Comparison of O transfer characteristics between a new centrifugal impeller and a flat-bladed turbine impeller

The efficiency of O transfer by a novel centrifugal impeller was higher than that of a conventional flat-bladed turbine impeller at an agitation speed lower than 300 rpm. In addition, at the same agitation speed (200 and 300 rpm), the centrifugal impeller possessed smaller shear stress than the flat-bladed turbine impeller as evaluated by the changes in size distribution of granulated agar particles which were sheared with those two types of impeller.     

A novel centrifugal impeller bioreactor. I. Fluid circulation, mixing, and liquid velocity profiles

A novel centrifugal impeller bioreactor for shear-sensitive biological systems was designed by installing a centrifugal-pumplike impeller in a stirred vessel. The fluid circulation, mixing, and liquid velocity profiles in the new bioreactor (5-L) were assessed as functions of the principal impeller designing and bioreactor operating parameters. The performances of the centrifugal impeller bioreactor were compared with those of a widely used cell-lift bioreactor. The newly developed bioreactor showed higher liquid lift capacity and shorter mixing time than the cell lift with comparable dimensions. Furthermore, the experiments of the liquid velocity profiles around an impeller region indicated that the centrifugal impeller bioreactor produced lower shear stress than the cell lift. This conclusion was also supported by evaluating the changes in size distributions of granulated agar particles that were sheared with those two types of impeller.     

Performance of mammalian cell culture bioreactor with a new impeller design

To improve the oxygen transfer in a mammalian cell bioreactor, a new type of impeller consisting of a double-screen concentric cylindrical cage impeller (annular cage impeller in short) was designed and its mass transfer rate evaluated. This new impeller design increases the specific screen area, and the convective mass transfer rate through the annular cage was significantly increased. The oxygen transfer rates with the new impeller and the commercially available cell-lift impeller (CelliGen by New Brunswick Scientific Co.) were evaluated and their performance compared at various rates of aeration and agitation. The results showed that with the new impeller, the oxygen transfer rate was increased by 19% in water and 21% in cell-free culture medium supplemented with 10% horse serum, the total hybridoma cell concentration was increased to 3.4 x 10(7) cells/mL, and the IgG(1) subtype monoclonal antibody (MAb) product concentration was also increased to 512 mg/L in perfusion culture of murine hybridoma cell line 62'D3. These improvements in oxygen transfer rate, cell concentration, and MAb product concentration are all very significant. The mass transfer resistance in the cell-lift impeller system was found to be mainly due to the surface area of the single-screen cage impeller. The new annular cage impeller not only provided the increased surface area for convective oxygen transfer but also protected cells from hydrodynamic shear damage, thereby achieving a significant bioprocess improvement in terms of higher viable cell concentration, higher product concentration, and higher oxygen transfer rate in the mammalian cell bioreactor system.     

Studies on mixing in horizontal rotating tubular bioreactor

A horizontal rotating tubular bioreactor (HRTB) is a combination of a “thin-layer bioreactor” and a “biodisc” reactor. Its interior is divided by O-ring shaped partition walls. Mixing properties of this new type of the bioreactor were investigated by using a temperature step method. The mixing simulations were done by Runge-Kutta-Fehlberg numerical integration. Adjustable parameters of the “spiral flow” model were optimised by Monte-Carlo method. In this investigation, the structured “spiral flow” model (containing four adjustable parameters) was tested in a wide range of experimental conditions. The results show that the structured “spiral flow” model is capable to describe the mixing in HRTB in the whole range of both bioreactor operational parameters (n and D).     

Studies on mixing in horizontal rotating tubular bioreactor

Mixing studies in the horizontal rotating tubular bioreactor (HRTB) were done to explore the influences of the liquid level (H _M =0.050.08 m) and the distance between the partition walls (D _S =0.020.07 m) on the mixing performance in the bioreactor described by the “spiral flow” model. The optimised adjustable parameters of the model were correlated with the process parameters of the bioreactor expressed as dimensionless numbers: Reynolds rotation number (Re _N ) and Reynolds axial flow number (Re _D ). The polynomial coefficients of the correlations were correlated further with the liquid level in the bioreactor (H _M ) and the distance between the partition walls (D _S ). In that way, three modified prediction systems (SC-2A, SC-6A and SC-9A) were established. The analysis based on different criteria selected the prediction system SC-9A as the most suitable to describe the mixing performance of HRTB.     

Studies on mixing in horizontal rotating tubular bioreactor

In previous investigations on mixing in a horizontal rotating tubular bioreactor (HRTB) the structured “spiral flow” model was developed which contained four adjustable parameters [1, 2]. In order to incorporate the mixing model in a semifundamental scale-up procedure it was necessary to make a relation between the adjustable model parameters and process parameters of the bioreactor expressed as dimensionless numbers. Mathematical equations which relate adjustable model parameters with dimensionless numbers were developed by non-linear and surface regression methods. These equations were applied to develop the prediction systems for adjustable model parameters. In total, nine systems of equations for the prediction of the adjustable model parameters were established and examined by simulation. Three of them (SC-2, SC-6 and SC-9) were selected as adequate to describe the mixing performance of HRTB in a wide range of process conditions.     

Oxygen transfer rates in a mammalian cell culture bioreactor equipped with a cell-lift impeller

Measurements of k(L)a were carried out in 1. 5- and 5-L New Brunswick Scientific CelliGen(R) bioreactors. The measured k(L)a in water were identical for both vessel sizes operated in similar condition. The mass transfer rate increased with temperature, mixing speed, and aeration rate, with this last parameter being the most significant. Surface aeration alone gave k(L)a values of 0. 4 to 1. 6 h(-1). A 25% decrease in k(L)a was observed above an aeration rate of 1. 6 vvm. This was caused by the particular foam breaker of the CelliGen bioreactor. Measurements of k(L)a using a mammalian cell culture medium supplemented with 5% fetal calf serum (FCS) have confirmed the negative effect of the foam breaker on k(L)a The measured value in this medium was 1. 2 h(-1) for all aeration rates, more than 60% of which was attributed to surface aeration.     

Pullulan fermentation using a prototype rotational reciprocating plate impeller

A rotational reciprocating plate impeller prototype, designed to improve the mixing homogeneity of viscous non-Newtonian fermentation broth, has been tested in pullulan fermentations. With this new impeller, the operating levels of several factors were investigated to improve pullulan production with Aureobasidium pullulans ATCC 42023 in a 22-L bioreactor using experimental designs. Because both high molecular weight (MW) and high concentration of pullulan were desired; the exopolysaccharide (EPS) concentration and the broth viscosity were used as optimization objective functions to be maximized. A 6-run uniform design was used to investigate five factors. Under the best operating conditions among the six runs, 29.0 g L^?1 EPS was produced at 102 h. This condition was used as the starting point for further investigation on the two statistically significant factors, the pH and the agitation speed. An 8-run 3-level custom design that investigates up to second-order effects was used in the second stage. An optimal zone of operating conditions for large quantity of high MW pullulan production was identified. A concentration of 23.3 g L^?1 EPS was produced at 78 h. This is equivalent to an EPS productivity of 0.30 g L^?1 h^?1. The corresponding apparent viscosity of the broth was 0.38 Pa s at the shear rate of 10 s^?1.     

Disintegration of yeast Saccharomyces cerevisiae in the vertical perl mill with a bell-shaped impeller

Investigation of disintegration of yeast Saccharomyces cerevisiae in the laboratory batch perl mill with a bell-shaped impeller was carried out. The number of non-damaged cells, changing in time was determined using hemocytometer (Thom's chamber).To describe kinetics of the disintegration process the differential equation was applied: where N _p the number of non-damaged cells in the sample, [number of cells/ml] t time, [s] m,k constants.The effect of three operating parameters: rotation frequency of the impeller shaft n, filling of the mill with disintegrating elements (ballotini) S _k and the initial concentration of yeast cells in the suspension C ₀ on the process of disintegration was analyzed.For S _k =0.5, m=1 and dependence of constant k on the rotation frequency of the impeller and suspension concentration were obtained. For S _k =0.6 and 0.7 the values of m were higher than 1. The effect of rotation frequency of the impeller and filling of the mill, with ballotini on constant k and exponent m was determined.List of Symbols a, b constants - a ₁, b ₁, c ₁, d ₁ constants - C ₀ initial concentration of suspension g/ml - C concentration of cell suspension g/ml - k constant disintegration rate 1/s; N ₀ ^1-m /s - m variable in the equation - N ₀ initial number of cells no. of cells/ml - N _p number of non-damaged cells no. of cells/ml - r process rate g/ml·s - X(t) disintegration degree % - , variables in the equation - z variable in the equation - S _k degree of filling the mill with disintegrating elements     

Production of somatic embryos in a helical ribbon impeller bioreactor

Embryogenic cultures of a transformed Eschscholtzia californica cell line were carried out in a 11-L helical ribbon impeller bioreactor operated under various conditions to evaluate the performance of this equipment for somatic embryo (SE) production. All bioreactor cultures produced SE suspensions with maximum concentrations at least comparable to those obtained from flask control cultures ( approximately 8-13 SE . mL(-;1)). However, an increase of the mixingspeed, from 60 to 100 rpm, and low sparging rate ( approximately 0.05 VVM, k(L) a approximately 6.1 h(-;1)) for dissolved oxygen concentration (DO) control yielded poorer quality embryogenic cultures. The negative effects on SE production were attributed mainly to the low but excessive shear experienced by the embryogenic cells and/or embryoforming aggregates. High DO ( approximately 60% of air saturation) conditions favored undifferentrated biomass production and high nutrient uptake rates at the expense of the slower SE differentiation process in both flask and bioreactor cultures. Too low DO (-5-10%) inhibited biomass and SE production. The best production of SE ( approximately 44 SE . mL(-1) or approximately 757 SE . g dw(-1) . d(-1)) was achieved by operating the bioreactor at 60 rpm while controlling DO at approximately 20%by surface oxygenation only (0.05 VVM, k(L) a approximately 1.4 h(-;1)). This production was found to be a biomass production/growth-associated process and was mainly limited by the availability of extracellular phosphate, magnesium, nitrogen salts, and carbohydrates. (c) 1994 John Wiley & Sons, Inc.     

Carbon monoxide mass transfer for syngas fermentation in a stirred tank reactor with dual impeller configurations

This study compares the power demand and gas-liquid volumetric mass transfer coefficient, kLa, in a stirred tank reactor (STR) (T = 0.211 m) using different impeller designs and schemes in a carbon monoxide-water system, which is applicable to synthesis gas (syngas) fermentation. Eleven different impeller schemes were tested over a range of operating conditions typically associated with the "after large cavity" region (ALC) of a Rushton-type turbine (D/T = 0.35). It is found that the dual Rushton-type impeller scheme exhibits the highest volumetric mass transfer rates for all operating conditions; however, it also displays the lowest mass transfer performance (defined as the volumetric mass transfer coefficient per unit power input) for all conditions due to its high power consumption. Dual impeller schemes with an axial flow impeller as the top impeller show improved mass transfer rates without dramatic increases in power draw. At high gas flow rates, dual impeller schemes with a lower concave impeller have kLa values similar to those of the Rushton-type dual impeller schemes but show improved mass transfer performance. It is believed that the mass transfer performance can be further enhanced for the bottom concave impeller schemes by operating at conditions beyond the ALC region defined for Rushton-type impellers because the concave impeller can handle higher gas flow rates prior to flooding.     

Studies supporting the use of mechanical mixing in large scale beer fermentations

Brewing fermentations have traditionally been undertaken without the use of mechanical agitation, with mixing being provided only by the fluid motion induced by the CO₂ evolved during the batch process. This approach has largely been maintained because of the belief in industry that rotating agitators would damage the yeast. Recent studies have questioned this view. At the bench scale, brewer’s yeast is very robust and withstands intense mechanical agitation under aerobic conditions without observable damage as measured by flow cytometry and other parameters. Much less intense mechanical agitation also decreases batch fermentation time for anaerobic beer production by about 25% compared to mixing by CO₂ evolution alone with a small change in the concentration of the different flavour compounds. These changes probably arise for two reasons. Firstly, the agitation increases the relative velocity and the area of contact between the cells and the wort, thereby enhancing the rate of mass transfer to and from the cells. Secondly, the agitation eliminates spatial variations in both yeast concentration and temperature, thus ensuring that the cells are maintained close to the optimum temperature profile during the whole of the fermentation time. These bench scale studies have recently been supported by results at the commercial scale from mixing by an impeller or by a rotary jet head, giving more consistent production without changes in final flavour. It is suggested that this reluctance of the brewing industry to use (adequate) mechanical agitation is another example where the myth of shear damage has had a detrimental effect on the optimal operation of commercial bioprocessing.     

Studies of the mixing character and flow distribution in mycelial fermentation broths

The influence of two mixing systems on the principal parameters of mycelial fermentations of Aspergillus niger, Fusicoccum amygdali Del. and Fusarium moniliforme Sheld. as well as their metabolite citric acid, fusicoccin and gibberellic acid production was analyzed from the viewpoint of flow energy distribution in a bioreactor. The growth and metabolite synthesis during fermentation was compared under different mixing conditions in the fermenter FU-8 with a turbine mixing system (TMS) and a counterflow mixing system (CMS). It was found that the growth, productivity and respiration characteristics as well as the morphology of these cultures varied dependent on the mixing system and agitation regime used. The counterflow mixing system was more favourable for large agglomerates (F. amygdali) or soft pellets (A. niger) forming fungi, while the turbine mixing system was more effective for F. moniliforme growing in the form of small clumps and freely dispersed hyphae. Flow characteristics under different mixing conditions were analyzed in a model fermenter. The kinetic energy of flow fluctuations was measured in gassed and ungassed water and different fermentation broth systems by using a Stirring Intensity Measuring Device (SIMD-F1). The difference of the energy values at different points was better expressed in the fermenter with a turbine mixing system in comparison with that having a counterflow mixing system. High viscous F. amygdali and A. niger broth provided higher energy values compared to water and low viscous F. moniliforme broth. It was observed that the intensity of growth and the intensity of the synthesis decreased at very high energy values, which was obviously connected to the influence of the irreversible shear stress on the mycelial morphology.     

Effects of increased impeller power in a production-scale Aspergillus oryzae fermentation

The goal in this study was to determine how increased impeller power affects enzyme expression in large-scale (80 m(3)), fed-batch Aspergillus oryzae fermentations. An approximate 50% increase in average impeller power was achieved by increasing impeller diameter approximately 10%, while operating at slightly reduced speed. Measured decreases in terminal (95%) mixing time show increased power improved bulk mixing. However, batches operated at increased power had lower recombinant enzyme productivity. Biomass assays and image analysis tests showed no significant difference between "high power" and control batches, suggesting that slower growth, altered morphology, or increased hyphal fragmentation were not the cause of reduced productivity. Off-line tests on the shear-thinning, highly viscous broth show oxygen limitation occurred after transport through the air-liquid interface and imply the limitation may involve bulk mixing. Specifically, oxygen transfer may be limited to a small zone surrounding each impeller. When this is the case, oxygen mass transfer will be determined by both impeller shear and fluid circulation, which have been characterized with the energy dissipation/circulation function (EDCF). EDCF values during control fermentations were approximately constant at 25 kW m (-3) s(-1), while EDCF values during "high power" batches fell linearly from 40 to 15 kW m (-3) s(-1). The point at which "high power" EDCF values drop below those in control fermentations corresponds almost exactly with the point at which product titer stops increasing. Thus, our findings suggest oxygen mass transfer was less efficient during the latter half of "high power" fermentations because of reductions in impeller speed and subsequent decreases in EDCF values. This observation has clear implications during the scale-up of viscous fungal fermentations, implying that not only is the level of impeller power important, but also relevant is how this power is applied.     

Culture of photomixotrophic soybean and pine in a modified fermentor using a novel impeller

Photomixotrophic suspensions of Glycine max (soybean) and Pinus elliottii (slash pine) have been successfully cultured in a hybrid stirred tank photobioreactor using a novel cell-lift impeller. A cell-lift impeller exhibited cell viabilities over 90% and an average cell aggregate size of 1.0 mm or less. Flat-bladed turbines produced equivalent biomass to the cell-lift impeller, but cell viability was reduced (85%) and cell aggregate size increased (3-5 mm diameter). Maximum fresh weights of 82 g L(-1) (soybean) and 52 g L(-1) (slash pine) were achieved in 15 days using continuous lighting (90-100 muE m(-2) s(-1)) and supplemental 2% CO(2) inlet gas. Maximum biomass was achieved using an impeller speed of 60 rpm with air-flow rate of 0.2 vvm for the cell-lift impeller and the pair of flat bladed turbines. The lag and early exponential phases were characterized by (1) rapid hydrolysis of sucrose followed by preferential use of glucose and (2) a reduction in chlorophyll levels. Carbon dioxide (2%-5%) was an essential nutrient for photomixotrophic cell culture in the bioreactors.