Residence time distributions of gas flowing through rotating drum bioreactors

Residence time distribution studies of gas through a rotating drum bioreactor for solid-state fermentation were performed using carbon monoxide as a tracer gas. The exit concentration as a function of time differed considerably from profiles expected for plug flow, plug flow with axial dispersion, and continuous stirred tank reactor (CSTR) models. The data were then fitted by least-squares analysis to mathematical models describing a central plug flow region surrounded by either one dead region (a three-parameter model) or two dead regions (a five-parameter model). Model parameters were the dispersion coefficient in the central plug flow region, the volumes of the dead regions, and the exchange rates between the different regions. The superficial velocity of the gas through the reactor has a large effect on parameter values. Increased superficial velocity tends to decrease dead region volumes, interregion transfer rates, and axial dispersion. The significant deviation from CSTR, plug flow, and plug flow with axial dispersion of the residence time distribution of gas within small-scale reactors can lead to underestimation of the calculation of mass and heat transfer coefficients and hence has implications for reactor design and scale-up.     

Numerical simulations of the pulsating flow of cerebrospinal fluid flow in the cervical spinal canal of a Chiari patient

The flow of cerebrospinal fluid (CSF) in a patient-specific model of the subarachnoid space in a Chiari I patient was investigated using numerical simulations. The pulsating CSF flow was modeled using a time-varying velocity pulse based on peak velocity measurements (diastole and systole) derived from a selection of patients with Chiari I malformation. The present study introduces the general definition of the Reynolds number to provide a measure of CSF flow instability to give an estimate of the possibility of turbulence occurring in CSF flow. This was motivated by the fact that the combination of pulsating flow and the geometric complexity of the spinal canal may result in local Reynolds numbers that are significantly higher than the commonly used global measure such that flow instabilities may develop into turbulent flow in these regions. The local Reynolds number was used in combination with derived statistics to characterize the flow. The results revealed the existence of both local unstable regions and local regions with velocity fluctuations similar in magnitude to what is observed in fully turbulent flows. The results also indicated that the fluctuations were not self-sustained turbulence, but rather flow instabilities that may develop into turbulence. The case considered was therefore believed to represent a CSF flow close to transition.     

Turbulent shear stress measurements in the vicinity of aortic heart valve prostheses

A two dimensional laser Doppler anemometer system has been used to measure the turbulent shear fields in the immediate downstream vicinity of a variety of mechanical and bioprosthetic aortic heart valves. The measurements revealed that all the mechanical valves studied, created regions of elevated levels of turbulent shear stress during the major portion of systole. The tissue bioprostheses also created elevated levels of turbulence, but they were confined to narrow regions in the bulk of the flow field. The newer generation of bioprostheses create turbulent shear stresses which are considerably lower than those created by the older generation tissue valve designs. All the aortic valves studied (mechanical and tissue) create turbulent shear stress levels which are capable of causing sub-lethal and/or lethal damage to blood elements.     

Chaperon solvent plug design in size-exclusion chromatography protein refolding process

Although the chaperon solvent plug was reported as a strategy to reduce aggregation before the column inlet in SEC (size-exclusion chromatography) protein refolding process, the appropriate position at which sample injected and the volume of the chaperon solvent plug have not been elucidated. Therefore, the detail of chaperon solvent plug design was investigated in this work. Our results indicated that, to ensure good performances in the SEC refolding process, the appropriate front and tail volumes of chaperon solvent plug should be slightly larger than the optimal values, which depend on the flow dispersion from the injector to the column inlet. However, with the front volume more than the optimum, it could have an adverse effect on activity recovery but not the mass recovery, while no effect at all if the tail volume exceeded the optimum. Furthermore, it might be economical to replace the eluent (refolding buffer) after the tail of chaperon solvent plug with a cheaper one.     

In-vitro pulsatile flow visualization studies in a pulmonary artery model

In-vitro pulsatile flow visualization studies were conducted in an adult-sized pulmonary artery model to observe the effects of valvular pulmonic stenosis on the flow fields of the main, left and right pulmonary arteries. The flow patterns revealed that as the degree of stenosis increased, the jet-type flow created by the valve became narrower, and it impinged on the far (distal) wall of the left pulmonary artery further downstream from the junction of the bifurcation. This in turn led to larger regions of disturbed turbulent flow, as well as helical-type secondary flow motions in the left pulmonary artery, compared to the right pulmonary artery. The flow field in the main pulmonary artery also became more disturbed and turbulent, especially during peak systole and the deceleration phase. The flow visualization observations have been valuable in helping to conduct further quantitative studies such as pressure and velocity field mapping. Such studies are important to understanding the fluid mechanics characteristics of the main pulmonary artery and its two major branches.     

Oxygen mass transfer into aerated CMC solutions in a bubble column

Differing findings on the volumetric mass transfer coefficients k(L)a in CMC solutions in bubble column bioreactors have been reported in the literature. Therefore, oxygen mass transfer was studied again in CMC solutions in a 14-cm-i.d. x 270-cm-height bubble column using different spargers. The k(L)a values were determined along with the dispersion coefficients by fitting the prediction of the axial dispersed plug model with the experimental oxygen concentration profiles in the liquid phase. Surprisingly, the obtained liquid phase dispersion coefficients for CMC solution are higher than one would expect from correlations. The k(L)a data depend largely on the flow regime. In general, they are lower than those reported in the literature. The data for developing slug and established slug flow are dependent on the gas velocity and the effective viscosity of the solution and can br correlated by a simple correlation. This correlation describes k(L)a values measured on fermentation broth of Penicillium chrysogenum with striking agreement.     

A novel continuous centrifugal bioreactor for high-density cultivation of mammalian and microbial cells

A continuous centrifugal bioreactor (CCBR), developed to study the growth and productivity of dense suspensions cultures, has been applied to both fermentation and mammalian cell cultivation processes. With this approach, high-density nonflocculent cultures are maintained in a tapered fluidized bed by balancing the drag forces on the cells due to following substrate with the centrifugal forces. The Sysyem was first used to produce ethanol by fermentation with Saccharomyces cerevisiae; then with H21A1 mouse hybridoma cells secreting monoclonal antibody (MoAb), lgM. Results of this research show the feasibility of using the CCBR for both production of secreted products and as a research tool for studying cell metabolism and production kinetics. Media recycle may be used to modify the behavior of the system form a plug flow apparatus to a continuous stirred reactor (CSTR).     

Investigation of how agitation during precipitation,and subsequent processing affects the particle size distribution and separation of α-lactalbumin enriched whey protein precipitates

In this work, α-lactalbumin (α-la) rich precipitate particles are formed and aged in a batch stirred-tank from a whey protein concentrate (WPC) dispersion. Precipitation of the proteins occurs during a period of acid-addition followed by an ageing period. This study investigates how stirred-tank impeller agitation and subsequent processing, by means of passing precipitate suspensions through a capillary tube or a partially open ball-valve, affect particle size and composition. Precipitate particles are largely unaffected when subjected to laminar capillary tube flow. However, as flow becomes transitional and thereafter turbulent, particle breakage increases, especially for precipitates formed and aged under mild agitation conditions. Precipitates passed through the ball-valve experience even greater particle size reduction as a sharp geometrical transition results in highly turbulent flow. Moreover, particles formed and aged under low shear conditions, though initially larger, are in fact weaker and fragment to a greater extent during turbulent processing through the ball-valve. This has process design implications for separation processes where particle size is important, as shear history can influence particle toughness. Substantial size reduction of particles can best be mitigated by identifying regions of high turbulence or sudden changes in flow geometry, and by redesigning these regions so as to reduce these effects.     

Production of ethanol by coupling fermentation and solvent extraction

Summary A new technology of fermentation is proposed. The inhibitor product is removed continuously by coupling fermentation and solvent extraction. Applied to ethanol fermentation this technology is suitable to any case where the terminal product is inhibitory.The proposed technology uses both plug flow reactor and liquid-liquid extraction to achieve continuously the extractive fermentation of ethanol. The solvent used for liquid-liquid extraction is dodecanol. A new reactor was used. It is a column packed with a porous material . The fermentation broth is pulsed (a) to increase the interfacial area between the liquid medium and the dodecanol, and (b) to: decrease the gas hold up.Alcoholic fermentations were performed on glucose syrup at 35°C using Saccharomyces cerevisiae, with adsorbed cells as reference, with adsorbed cells and extractive fermentation. The results show that the fermentation is substantially improved. By this new method the ethanol productivity was multiplied by 5 and a solution of 407 g/l of glucose was totally fermented with a yeast which cannot normally transform more than 200 g/l glucose.     

Low Reynolds number turbulence modeling of blood flow in arterial stenoses.

Moderate and severe arterial stenoses can produce highly disturbed flow regions with transitional and or turbulent flow characteristics. Neither laminar flow modeling nor standard two-equation models such as the kappa-epsilon turbulence ones are suitable for this kind of blood flow. In order to analyze the transitional or turbulent flow distal to an arterial stenosis, authors of this study have used the Wilcox low-Re turbulence model. Flow simulations were carried out on stenoses with 50, 75 and 86% reductions in cross-sectional area over a range of physiologically relevant Reynolds numbers. The results obtained with this low-Re turbulence model were compared with experimental measurements and with the results obtained by the standard kappa-epsilon model in terms of velocity profile, vortex length, wall shear stress, wall static pressure, and turbulence intensity. The comparisons show that results predicted by the low-Re model are in good agreement with the experimental measurements. This model accurately predicts the critical Reynolds number at which blood flow becomes transitional or turbulent distal an arterial stenosis. Most interestingly, over the Re range of laminar flow, the vortex length calculated with the low-Re model also closely matches the vortex length predicted by laminar flow modeling. In conclusion, the study strongly suggests that the proposed model is suitable for blood flow studies in certain areas of the arterial tree where both laminar and transitional/turbulent flows coexist.     

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)).     

Particle image velocimetry (PIV) study of rotating cylindrical filters for animal cell perfusion processes

In the present work, the main fluid flow features inside a rotating cylindrical filtration (RCF) system used as external cell retention device for animal cell perfusion processes were investigated using particle image velocimetry (PIV). The motivation behind this work was to provide experimental fluid dynamic data for such turbulent flow using a high‐permeability filter, given the lack of information about this system in the literature. The results shown herein gave evidence that, at the boundary between the filter mesh and the fluid, a slip velocity condition in the tangential direction does exist, which had not been reported in the literature so far. In the RCF system tested, this accounted for a fluid velocity 10% lower than that of the filter tip, which could be important for the cake formation kinetics during filtration. Evidence confirming the existence of Taylor vortices under conditions of turbulent flow and high permeability, typical of animal cell perfusion RCF systems, was obtained. Second‐order turbulence statistics were successfully calculated. The radial behavior of the second‐order turbulent moments revealed that turbulence in this system is highly anisotropic, which is relevant for performing numerical simulations of this system. © 2012 American Institute of Chemical Engineers Biotechnol. Prog., 2012     

Rapid ethanol fermentation with immobilized Zymomonas mobilis in a three stage reactor system

Summary Using the Zymomonas mobilis NRRL B 14023 strain for ethanol fermentation with immobilized cells the combination of two external loop reactors followed by a plug flow reactor was the most effective reactor configuration. A maximal productivity of 92 and 108 g/l·h at practically complete sugar consumption was obtained with Carrageenan and Alginate catalysts respectively. Due to the high dilution rate nonsterile operation for extended periods of weeks was possible.     

Mammalian cell damage in a novel membrane bioreactor

The experimental study has assessed a novel membrane bioreactor for mammalian cell culture. In the absence of a gas phase, the key features of cell damage associated with laminar and turbulent flow have been identified. The bioreactor employs a dimpled membrane in order to enhance transverse mixing in a narrow channel, but a fall in viable cell density has been observed at Reynolds numbers above Re = 83. In the laminar flow regime wall shear is the critical mechanism and an accurate calculation of shear rate in a complex channel has been achieved using the Reynolds analogy. Flow generating a wall shear rate in excess of 3000 s(-1) has been shown to cause damage. Power dissipation measurements have been used to distinguish between laminar and turbulent flow and also to predict Kolmogorov eddy lengths. An additional turbulent bulk stress damage mechanism at higher Reynolds numbers (Re > 250) results in a very rapid fall in viable cell density.     

A unique phenotypic modification of Lactococcus lactis cultivated in a Couette bioreactor

Batch cultures of Lactococcus lactis NCDO 2118 and IL 1403 were performed in a Couette bioreactor operated in the modulated wavy vortex flow and the turbulent regimes. This study provides an overall analysis taking into account both mechanical stress and mixing in a Couette bioreactor. A unique phenotypic aspect has been proved to occur only in the modulated wavy vortex flow regime for the two studied strains, namely that the cells become entrapped in a filamentous form. No change in the metabolic behavior of the cells has been observed. The polymeric matrix has been microscopically observed through FISH and fluorescent lectin binding, showing cells entrapped in a glycoconjugate matrix. All hypotheses regarding insufficient mixing as a cause of this phenotype have been discarded, leading to the conclusion that this particular phenotypic feature is essentially due a combined effect of mechanical stress and flow structure. Particle size measurement during the fermentation course indicates that formation of filamentous form results from a continuous aggregation started in the early stages of the cultivation. According to our results a minimum shear is required to induce the ability for cells to aggregate. Then, it appears that both flow structure and mechanical stress (shear) are responsible for the appearance of such a filamentous form. As far as the authors know, this is the first experimental evidence of a bio polymerization induced by the flow structure.     

Integration of Gas Enhanced Oil Recovery in Multiphase Fermentations for the Microbial Production of Fuels and Chemicals

In multiphase fermentations where the product forms a second liquid phase or where solvents are added for product extraction, turbulent conditions disperse the oil phase as droplets. Surface‐active components (SACs) present in the fermentation broth can stabilize the product droplets thus forming an emulsion. Breaking this emulsion increases process complexity and consequently the production cost. In previous works, it has been proposed to promote demulsification of oil/supernatant emulsions in an off‐line batch bubble column operating at low gas flow rate. The aim of this study is to test the performance of this recovery method integrated to a fermentation, allowing for continuous removal of the oil phase. A 500 mL bubble column is successfully integrated with a 2 L reactor during 24 h without affecting cell growth or cell viability. However, higher levels of surfactants and emulsion stability are measured in the integrated system compared to a base case, reducing its capacity for oil recovery. This is related to release of SACs due to cellular stress when circulating through the recovery column. Therefore, it is concluded that the gas bubble‐induced oil recovery method allows for oil separation and cell recycling without compromising fermentation performance; however, tuning of the column parameters considering increased levels of SACs due to cellular stress is required for improving oil recovery.     

Integration of mixing, heat transfer, and biochemical reaction kinetics in anaerobic methane fermentation

An extensive investigation of anaerobic methane fermentation requires identifying the relationship between the physical environment and biological process. In this study, a computational fluid dynamics (CFD) technique was used to characterize bacterial fermentation mechanisms intertwined with mixing and heat transfer in anaerobic digesters. The results demonstrate that the methane yield remains almost unchanged while the energy efficiency decreases with increasing mixing power in a complete‐mix digester, and that the energy output increases nonlinearly with the increase in heating energy in a plug‐flow digester. The CFD method can be applied to other bioreactors to gain valuable insights into their behavior as well. Integrating flow and temperature with kinetic behavior for anaerobic digestion not only solves the controversy about how mixing influences the digestive process, but also assists in optimizing the digester design and increasing the efficiency of energy conversion, and additionally, provides a reference for improving the mixing guidelines recommended by the U.S. Environmental Protection Agency. Biotechnol. Bioeng. 2012; 109: 2864–2874. © 2012 Wiley Periodicals, Inc.     

Periodic fluid extrusion and models of digesta mixing in the intestine of a herbivore,the common brushtail possum (<Emphasis Type="Italic">Trichosurus vulpecula</Emphasis>)

The digesta in four gut compartments (proximal and distal halves of small intestine, caecum, and proximal colon) of a wild hindgut fermenting herbivore, the common brushtail possum (Trichosurus vulpecula), were investigated by rheometry and permeametry. Digesta from all compartments were highly viscous and exhibited shear-thinning. Apparent viscosity was positively related to dry matter content, and increased from proximal small intestine to colon. Dynamic rheological measurements showed that in small intestinal digesta the elastic modulus was greater than the viscous modulus and their ratios were characteristic of weak gels, indicating that digesta could sustain compression. The apparent viscosity of distal small intestinal digesta was markedly lower when measured by capillary viscometry than by rotatory viscometry, indicating that plug flow was likely to be facilitated by lubrication from a peripheral layer of less viscous fluid; i.e., there was an augmented plug flow. Permeametry showed that fluid was extruded from all digesta on compression at physiological pressures, that there was significant permeability of proximal and distal small intestinal digesta, but that digesta became progressively compacted during permeation, with a concomitant reduction in permeability as dry matter content increased. It is proposed that conditions within the small intestine differ from those of an ideal plug flow reactor as radial mixing and turbulence cannot occur. Instead, we suggest that segmentation and peristalsis aid radial mixing of the fluid phase by compressing the solid phase, with extrusion of fluid through the digesta plug. This extrusion may be followed by resorption of fluid back into the plug when the elasticity of the solid phase of digesta is Hookean, thus aiding the mixing of secreted enzymes with insoluble substrates within the plug.