CFD simulation of non-Newtonian fluid flow in anaerobic digesters

A general mathematical model that predicts the flow fields in a mixed-flow anaerobic digester was developed. In this model, the liquid manure was assumed to be a non-Newtonian fluid, and the flow governed by the continuity, momentum, and k-epsilon standard turbulence equations, and non-Newtonian power law model. The commercial computational fluid dynamics (CFD) software, Fluent, was applied to simulate the flow fields of lab-scale, scale-up, and pilot-scale anaerobic digesters. The simulation results were validated against the experimental data from literature. The flow patterns were qualitatively compared for Newtonian and non-Newtonian fluids flow in a lab-scale digester. Numerical simulations were performed to predict the flow fields in scale-up and pilot-scale anaerobic digesters with different water pump power inputs and different total solid concentration (TS) in the liquid manure. The optimal power inputs were determined for the pilot-scale anaerobic digester. Some measures for reducing dead and low velocity zones were proposed based upon the CFD simulation results.     

A Desktop Apparatus for Studying Interactions Between Microorganisms and Small-Scale Fluid Motion

Low levels of kinetic energy dissipation were successfully generated in a reactor using two submersible speakers. A software programme controlled the amplitude and frequency of the signal fed to each speaker and achieved good repeatability of flow conditions. The flow reactor had a near isotropic flow regime with a low mean flow, values were calculated from particle image velocimetry measurements. The flow characteristics compared well with grid turbulence reactors, though as no moving parts are present in this reactor design the strain rates were lower compared to oscillating grid set-ups. The low range of Reynolds numbers based on Taylor microscales (Re_λ~0.5–5.9) covered both turbulent and non-turbulent flow regimes. The small-scale fluid motion produced over the entire volume of this reactor makes it suitable for experiments examining the physiological responses of fluid motion on microorganisms.     

Influence of biogas-induced mixing on granulation in UASB reactors

Studies have been carried out to correlate biogas-induced mixing and granulation in upflow anaerobic sludge blanket (UASB) reactors, treating low-strength as well as high-strength biodegradable wastewaters. A dimensionless granulation index (GI) has been framed taking into account the mixing in sludge bed due to produced biogas. Analysis of full-scale, pilot-scale and lab-scale UASB reactors treating actual wastewaters reveals the significance of biogas-induced mixing, represented by GI, on granulation of biomass in the reactors. For obtaining proper granulation in UASB reactors (percentage granules greater than 50%, w/w), resulting in higher chemical oxygen demand (COD) removal efficiency, it is recommended to maintain GI values in the range of 15,000–57,000.     

Methods and milliliter scale devices for high-throughput bioprocess design

Based on electromagnetic simulations as well as on computational fluid dynamics simulations gas-inducing impellers and their magnetic inductive drive were optimized for stirred-tank reactors on a 10 ml-scale arranged in a bioreaction block with 48 bioreactors. High impeller speeds of up to 4,000 rpm were achieved at very small electrical power inputs (63 W with 48 bioreactors). The maxima of local energy dissipation in the reaction medium were estimated to be up to 50 W L⁻¹ at 2,800 rpm. Total power input and local energy dissipation are thus well comparable to standard stirred-tank bioreactors. A prototype fluorescence reader for 8 bioreactors with immobilized fluorometric sensor spots was applied for online measurement of dissolved oxygen concentration making use of the phase detection method. A self-optimizing scheduling software was developed for parallel control of 48 bioreactors with a liquid-handling system for automation of titration and sampling. It was shown on the examples of simple parallel batch cultivations of Escherichia coli with different media compositions that high cell densities of up to 16.5 g L⁻¹ dry cell mass can be achieved without pH-control within 5 h with a high parallel reproducibility (standard deviation<3.5%, n=48) due to the high oxygen transfer capability of the gas-inducing stirred-tank bioreactors.     

Homogenisation and oxygen transfer rates in large agitated and sparged animal cell bioreactors: Some implications for growth and production

Because of concern for cell damage, very low agitation energy inputs have been used in industrial animal cell bioreactors, typical values being two orders of magnitude less than those found in bacterial fermentations. Aeration rates are also very small. As a result, such bioreactors might be both poorly mixed and also unable to provide the higher oxygen up-take rates demanded by more intensive operation. This paper reports experimental studies both of K _L a and of mixing (via pH measurements) in bioreactors up to 8 m³ at Wellcome and of scaled down models of such reactors at Birmingham. Alongside these physical measurements, sensitivity of certain cell lines to continuously controlled dO₂ has been studied and the oxygen up-take rates measured in representative growth conditions. An analysis of characteristic times and mixing theory, together with other recent work showing that more vigorous agitation and aeration can be used especially in the presence of Pluronic F-68, indicates ways of improving their performance. pH gradients offer a special challenge.     

A quantitative study of eicosapentaenoic acid (EPA) production by Nannochloropsis gaditana for aquaculture as a function of dilution rate,temperature and average irradiance

Different pilot-scale outdoor photobioreactors using medium recycling were operated in a greenhouse under different environmental conditions and the growth rates (0.1 to 0.5 day^?1) obtained evaluated in order to compare them with traditional systems used in aquaculture. The annualized volumetric growth rate for Nannochloropsis gaditana was 0.26 g l^?1 day^?1 (peak 0.4 g l^?1 day^?1) at 0.4 day^?1 in a 5-cm wide flat-panel bioreactor (FP-PBR). The biomass productivity achieved in this reactor was 10-fold higher than in traditional reactors, reaching values of 28 % and 45 % dry weight (d.w.) of lipids and proteins, respectively, with a 4.3 % (d.w.) content of eicosapentaenoic acid (EPA). A model for predicting EPA productivity from N. gaditana cultures that takes into account the existence of photolimitation and photoinhibition of growth under outdoor conditions is presented. The effect of temperature and average irradiance on EPA content is also studied. The maximum EPA productivity attained is 30 mg l^?1 day^?1.     

Hydrodynamic performance of pilot-scale duckweed,algal-based,rock filter and attached-growth media reactors used for waste stabilisation pond research

The specific nature of fluid dynamics within waste stabilisation ponds can have a determining influence on their functional treatment performance. This paper presents the results of hydraulic tracer experiments undertaken to characterise the hydrodynamic behaviour of several pilot-scale advanced pond treatment systems (a duckweed-based pond, a conventional algal-based ‘open’ pond, a rock filter and a novel horizontal-flow attached-growth media reactor) investigated for their effectiveness at polishing a full-scale tertiary pond effluent. Duplicate tracer studies were undertaken for each of the four experimental reactors with the aid of the fluorescent dye rhodamine WT. Results from tracer studies showed flow distribution in all reactors to be highly dispersed with varying degrees of dead space volume and short-circuiting in all pilot reactors, indicating that a percentage of the total reactor volume across all treatment systems was inactive. Results from a number of calculated parameters of hydraulic performance showed that hydrodynamic efficiency was greatest in the novel horizontal-flow attached-growth media system, where a possible baffling of inflowing wastewater was thought to have promoted improved hydraulic operation. Outcomes from this research in general highlight the importance of undertaking detailed characterisations of the hydrodynamic operation of experimental pond systems and also emphasise the value of pre-validating the hydraulic design of experimental reactors used for stabilisation pond research.     

Ultrahigh-cell-density heterotrophic cultivation of the unicellular green microalga Scenedesmus acuminatus and application of the cells to photoautotrophic culture enhance biomass and lipid production

Although production of biodiesels from microalgae is proved to be technically feasible, a commercially viable system has yet to emerge. High-cell-density fermentation of microalgae can be coupled with photoautotrophic cultivation to produce oils. In this study, by optimizing culturing conditions and employing a sophisticated substrate feed control strategy, ultrahigh-cell-density of 286 and 283.5 g/L was achieved for the unicellular alga Scenedesmus acuminatus grown in 7.5-L bench-scale and 1,000-L pilot-scale fermenters, respectively. The outdoor scale-up experiments indicated that heterotrophically grown S. acuminatus cells are more productive in terms of both biomass and lipid accumulation when they are inoculated in photobioreactors for lipid production as compared to the cells originally grown under photoautotrophic conditions. Technoeconomic analysis based on the pilot-scale data indicated that the cost of heterotrophic cultivation of microalgae for biomass production is comparable with that of the open-pond system and much lower than that of tubular PBR, if the biomass yield was higher than 200 g/L. This study demonstrated the economic viability of heterotrophic cultivation on large-scale microalgal inocula production, but ultrahigh-productivity fermentation is a prerequisite. Moreover, the advantages of the combined heterotrophic and photoautotrophic cultivation of microalgae for biofuels production were also verified in the pilot-scale.     

Energy conversion in an internally illuminated annular‐plate airlift photobioreactor

Algal‐derived therapeutics, bioactive molecules, and fuels produced in photobioreactors (PBRs) are of great scientific and economic interest, but the high cost of production still prevents their widespread use. Specifically, the cost of the energy inputs and the control of the photonic inputs that enable production optimization continue to be problematic. To this end, a novel 55‐L annular‐plate airlift PBR (APAPBR) with internal illumination was designed and characterized for the batch production of algal biomass. The APAPBR was able to convert mixing and photonic energy inputs into Chlorella pituita SG1 biomass at an efficiency of 0.064 (J biomass [J input]^?1), or 0.27 g dry cell weight (DW) W^?1 d^?1. Thanks to a high degree of photon capture and the airlift effect that provided energy‐efficient mixing and mass transfer, this energy conversion is 54% of the theoretical maximum as determined in previous studies. Under these efficiency conditions, C. pituita SG1 was able to grow photoautotrophically to 3.9 ± 0.2 gDW L^?1. Additionally, a mathematical approach was used to predict the mean light intensity with the highest biomass yield per unit of photonic input and the maximum biomass concentration achievable under the given process conditions. These predictions were validated in our system by the experimental cultivation data. This APAPBR represents a simple, innovative, and energy‐efficient PBR configuration that could decrease the cost of phototrophic bioprocesses and enable novel bioprocesses that require a high degree of control over the photonic input.     

Computational evaluation of Synechococcus sp. PCC 7002 metabolism for chemical production

Cyanobacteria are ideal metabolic engineering platforms for carbon-neutral biotechnology because they directly convert CO₂ to a range of valuable products. In this study, we present a computational assessment of biochemical production in Synechococcus sp. PCC 7002 (Synechococcus 7002), a fast growing cyanobacterium whose genome has been sequenced, and for which genetic modification methods have been developed. We evaluated the maximum theoretical yields (mol product per mol CO₂ or mol photon) of producing various chemicals under photoautotrophic and dark conditions using a genome-scale metabolic model of Synechococcus 7002. We found that the yields were lower under dark conditions, compared to photoautotrophic conditions, due to the limited amount of energy and reductant generated from glycogen. We also examined the effects of photon and CO₂ limitations on chemical production under photoautotrophic conditions. In addition, using various computational methods such as minimization of metabolic adjustment (MOMA), relative metabolic change (RELATCH), and OptORF, we identified gene-knockout mutants that are predicted to improve chemical production under photoautotrophic and/or dark anoxic conditions. These computational results are useful for metabolic engineering of cyanobacteria to synthesize value-added products.     

Computational simulations of airflow in an in vitro model of the pediatric upper airways

In order to understand mechanisms of gas and aerosol transport in the human respiratory system airflow in the upper airways of a pediatric subject (male aged 5) was calculated using Computational Fluid Dynamic techniques. An in vitro reconstruction of the subject's anatomy was produced from MRI images. Flow fields were solved for steady inhalation at 6.4 and 8 LPM. For validation of the numerical solution, airflow in an adult cadaver based trachea was solved using identical numerical methods. Comparisons were made between experimental results and computational data of the adult model to determine solution validity. It was found that numerical simulations can provide an accurate representation of axial velocities and turbulence intensity. Data on flow resistance, axial velocities, secondary velocity vectors, and turbulent kinetic energy are presented for the pediatric case. Turbulent kinetic energy and axial velocities were heavily dependant on flow rate, whereas turbulence intensity varied less over the flow rates studied. The laryngeal jet from an adult model was compared to the laryngeal jet in the pediatric model based on Tracheal Reynolds number. The pediatric case indicated that children show axial velocities in the laryngeal jet comparable to adults, who have much higher tracheal Reynolds numbers than children due to larger characteristic dimensions. The intensity of turbulence follows a similar trend, with higher turbulent kinetic energy levels in the pediatric model than would be expected from measurements in adults at similar tracheal Reynolds numbers. There was reasonable agreement between the location of flow structures between adults and children, suggesting that an unknown length scale correlation factor could exist that would produce acceptable predictions of pediatric velocimetry based off of adult data sets. A combined scale for turbulent intensity as well may not exist due to the complex nature of turbulence production and dissipation.     

Computational and experimental investigation of flow and fluid mixing in the roller bottle bioreactor

The fully three-dimensional velocity field in a roller bottle bioreactor is simulated for two systems (creeping flow and inertial flow conditions) using a control volume-finite element method, and validated experimentally using particle imaging velocimetry. The velocity fields and flow patterns are described in detail using velocity contour plots and tracer particle pathline computations. Bulk fluid mixing in the roller bottle is then examined using a computational fluid tracer program and flow visualization experiments. It is shown that the velocity fields and flow patterns are substantially different for each of these flow cases. For creeping flow conditions the flow streamlines consist of symmetric, closed three-dimensional loops; and for inertial flow conditions, streamlines consist of asymmetric toroidal surfaces. Fluid tracers remain trapped on these streamlines and are unable to contact other regions of the flow domain. As a result, fluid mixing is greatly hindered, especially in the axial direction. The lack of efficient axial mixing is verified computationally and experimentally. Such mixing limitations, however, are readily overcome by introducing a small-amplitude vertical rocking motion that disrupts both symmetry and recirculation, leading to much faster and complete axial mixing. The frequency of such motion is shown to have a significant effect on mixing rate, which is a critical parameter in the overall performance of roller bottles.     

CFD predicted pH gradients in lactic acid bacteria cultivations

The formation of pH gradients in a 700 L batch fermentation of Streptococcus thermophilus was studied using multi-position pH measurements and computational fluid dynamics (CFD) modeling. To this end, a dynamic, kinetic model of S. thermophilus and a pH correlation were integrated into a validated one-phase CFD model, and a dynamic CFD simulation was performed. First, the fluid dynamics of the CFD model were validated with NaOH tracer pulse mixing experiments. Mixing experiments and simulations were performed whereas multiple pH sensors, which were placed vertically at different locations in the bioreactor, captured the response. A mixing time of about 46 s to reach 95% homogeneity was measured and predicted at an impeller speed of 242 rpm. The CFD simulation of the S. thermophilus fermentation captured the experimentally observed pH gradients between a pH of 5.9 and 6.3, which occurred during the exponential growth phase. A pH higher than 7 was predicted in the vicinity of the base solution inlet. Biomass growth, lactic acid production, and substrate consumption matched the experimental observations. Moreover, the biokinetic results obtained from the CFD simulation were similar to a single-compartment simulation, for which a homogeneous distribution of the pH was assumed. This indicates no influence of pH gradients on growth in the studied bioreactor. This study verified that the pH gradients during a fermentation in the pilot-scale bioreactor could be accurately predicted using a coupled simulation of a biokinetic and a CFD model. To support the understanding and optimization of industrial-scale processes, future biokinetic CFD studies need to assess multiple types of environmental gradients, like pH, substrate, and dissolved oxygen, especially at industrial scale.     

Monitoring gradient formation in a jet aerated bioreactor

Jet aerated loop reactors (JLRs) provide high mass transfer coefficients (k_La) and can be used for the intensification of mass transfer limited reactions. The jet loop reactor achieves higher k_La values than a stirred tank reactor (STR). The improvement relies on significantly higher local power inputs (～10⁴) than those obtainable with the STR. Operation at high local turnover rates requires efficient macromixing, otherwise reactor inhomogeneities might occur. If sufficient homogenization is not achieved, the selectivity of the reaction and the respective yields are decreased. Therefore, the balance between mixing and mass transfer in jet loop reactors is a critical design aspect. Monitoring the dissolved oxygen levels during the turnover of a steady sodium sulfite feed implied the abundance of gradients in the JLR. Prolonged mixing times at identical power input and aeration rates (～100%) were identified for the JLR in comparison to the STR. The insertion of a draft tube to the JLR led to a more homogenous dissolved oxygen distribution, but unfortunately a reduction of mixing time was not achieved. In case of increased medium viscosities as they may arise in high cell density cultivations, no gradient formation was detected. However, differences in medium viscosity significantly altered the mass transfer and mixing performance of the JLR.     

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.     

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.     

Enhanced uptake of dissolved oxygen and glucose by <Emphasis Type="Italic">Escherichia coli</Emphasis> in a turbulent flow

Laboratory experiments were conducted to study the effect of turbulence on Escherichia coli cells in an oscillating grid reactor under conditions of no oxygen transfer to the liquid phase. Fluid flow was quantified at a submillimeter resolution using a particle image velocimetry measuring technique. The root-mean-square estimates of the velocity gradient tensor components indicated the dominance of shear rate deformation in the fluid surrounding E. coli. The E. coli growth rate, dissolved oxygen (DO), and glucose uptake rates were facilitated by fluid-flow energy dissipation in the turbulent fluid. The Kolmogorov length scale (eta(K)) and velocity (u( K )) underlined characteristic scales at which enhanced DO and glucose uptake by E. coli were determined in a turbulent flow in comparison to still-water controls. A first-order power-law relation between the mass transport to the cells and the moving fluid is developed. The combined effects of the enhanced rate of strain at eta(K) scale and uniform velocity at u(K) determined the facilitated DO and glucose fluxes to E. coli. The mass transport to the E. coli was modeled by the Sherwood (Sh)-Péclet (Pe) number relationship by Sh = 1 + 1.08Pe(uK)(0.62) where Pe(uK) is the Péclet number defined by the u(K) velocity scale. The proposed first-order model described experimental data fairly well.     

Computational fluid dynamics analysis of mixing and gas–liquid mass transfer in wave bag bioreactor

Single use bioreactors provide an attractive alternative to traditional deep-tank stainless steel bioreactors in process development and more recently manufacturing process. Wave bag bioreactors, in particular, have shown potential applications for cultivation of shear sensitive human and animal cells. However, the lack of knowledge about the complex fluid flow environment prevailing in wave bag bioreactors has so far hampered the development of a scientific rationale for their scale up. In this study, we use computational fluid dynamics (CFD) to investigate the details of the flow field in a 20-L wave bag bioreactor as a function of rocking angle and rocking speed. The results are presented in terms of local and mean velocities, mixing, and energy dissipation rates, which are used to create a process engineering framework for the scale-up of wave bag bioreactors. Proof-of-concept analysis of mixing and fluid flow in the 20-L wave bag bioreactor demonstrates the applicability of the CFD methodology and the temporal and spatial energy dissipation rates integrated and averaged over the liquid volume in the bag provide the means to correlate experimental volumetric oxygen transfer rates (k_La) data with power per unit volume. This correlation could be used as a rule of thumb for scaling up and down the wave bag bioreactors.     

A novel low-cost thin-film flat plate photobioreactor for microalgae cultivation

In this study, a novel thin-film flat plate photobioreactor (FPPBR) mounted with baffles and a 61.2 m² (2,000 L) photobioreactor system based on the FPPBR were developed. The flow of the fluid in the thinfilm photobioreactor was investigated by means of computational fluid dynamics (CFD). The cultivation of Chlorella sp. and Scenedesmus dimorphus in the thin-film FPPBR was carried out outdoors. The results showed that the flow of culture medium in different channels was uniform. In outdoor cultivation, the biomass productivity in the FPPBR with baffles was 25.2% higher than that in the FPPBR without baffles. In the pilot-scale FPPBR system, the maximum area productivity of Scenedesmus dimorphus reached 21.9 g/m²/day. When the service time of the photobioreactor was 1 and 3 years, the capital cost of the photobioreactor was 4.72 and 2.45 $ kg_algae, respectively. The results demonstrated that the thin-film FPPBR was cost effective, and it has the potential to be used for mass cultivation of microalgae.