The influence of polymeric membrane gas spargers on hydrodynamics and mass transfer in bubble column bioreactors

Gas sparging performances of a flat sheet and tubular polymeric membranes were investigated in 3.1 m bubble column bioreactor operated in a semi batch mode. Air–water and air–CMC (Carboxymethyl cellulose) solutions of 0.5, 0.75 and 1.0 % w/w were used as interacting gas–liquid mediums. CMC solutions were employed in the study to simulate rheological properties of bioreactor broth. Gas holdup, bubble size distribution, interfacial area and gas–liquid mass transfer were studied in the homogeneous bubbly flow hydrodynamic regime with superficial gas velocity (U _G) range of 0.0004–0.0025 m/s. The study indicated that the tubular membrane sparger produced the highest gas holdup and densely populated fine bubbles with narrow size distribution. An increase in liquid viscosity promoted a shift in bubble size distribution to large stable bubbles and smaller specific interfacial area. The tubular membrane sparger achieved greater interfacial area and an enhanced overall mass transfer coefficient (K _La) by a factor of 1.2–1.9 compared to the flat sheet membrane.     

Bubble characteristics and mass transfer in an airlift reactor with multiple net draft tubes

A pilot scale airlift reactor with multiple net draft tubes was developed. The reactor, 29?cm in diameter and 300?cm height, had four modules of double net draft tubes. Bubble size, bubble number, gas holdup, and volumetric mass transfer coefficient were measured under different superficial air velocities. The air velocity had little effect on bubble size but had significant influence on bubble number. A bubble column was also investigated for comparison. The airlift reactor had a higher gas holdup and volumetric mass transfer coefficient than those in the bubble column. The draft tubes in the airlift reactor substantially improved the reactor performance.     

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     

Absorption of oxygen in highly viscous newtonian and non-Newtonian fermentation model media in bubble column bioreactors

Summary Mean relative gas holdup, slip velocity, bubble size distribution, mean specific interfacial area, and volumetric mass transfer coefficient of oxygen were estimated in sparged columns 14 cm in diameter and 380 and/or 390 cm high with two different aerator types (porous plate and injector nozzle) in highly viscous Newtonian (glycerol solutions) and non-Newtonian (CMC solutions) fluids.For the Newtonian liquids the above properties were estimated as function of the viscosity of the liquid. For the non-Newtonian liquids they were determined as function of the fluid consistency index and flow behavior index. Significant differences between Newtonian and non-Newtonian systems appear. In Newtonian medium k_L a drops with increasing viscosity and already approaches a constant value at =40 cP. In pseudoplastic medium k_L a varies with the fluid consistency and flow behavior indexes in the entire investigated range.In both of these systems the primary bubble population changes into two or three populations along the reactor: the medium bubbles gradually disappear and small and large bubbles are formed.     

Liquid-to-Gas Mass Transfer in Anaerobic Processes: Inevitable Transfer Limitations of Methane and Hydrogen in the Biomethanation Process

Liquid-to-gas mass transfer in anaerobic processes was investigated theoretically and experimentally. By using the classical definition of k(L)a, the global volumetric mass transfer coefficient, theoretical development of mass balances in such processes demonstrates that the mass transfer of highly soluble gases is not limited in the usual conditions occurring in anaerobic fermentors (low-intensity mixing). Conversely, the limitation is important for poorly soluble gases, such as methane and hydrogen. The latter could be overconcentrated to as much as 80 times the value at thermodynamic equilibrium. Such overconcentrations bring into question the biological interpretations that have been deduced solely from gaseous measurements. Experimental results obtained in three different methanogenic reactors for a wide range of conditions of mixing and gas production confirmed the general existence of low mass transfer coefficients and consequently of large overconcentrations of dissolved methane and hydrogen (up to 12 and 70 times the equilibrium values, respectively). Hydrogen mass transfer coefficients were obtained from the direct measurements of dissolved and gaseous concentrations, while carbon dioxide coefficients were calculated from gas phase composition and calculation of related dissolved concentration. Methane transfer coefficients were based on calculations from the carbon dioxide coefficients. From mass balances performed on a gas bubble during its simulated growth and ascent to the surface of the liquid, the methane and carbon dioxide contents in the gas bubble appeared to be controlled by the bubble growth process, while the bubble ascent was largely responsible for a slight enrichment in hydrogen.     

Measurement of interfacial areas in aerobic fermentations by ultrasonic pulse transmission

The penetration of ultrasonic waves through opaque media and the large difference in the acoustic properties between air bubbles and the fermentation broth were used to measure the energy attenuation of pulsed ultrasound by the bubbles as the waves passed through the broth. This leads to an on-line determination of the specific interfacial area provided information is available about the holdup or bubble mean diameter. This article gives the principle of the method and demonstrates how the measured interfacial area may be used in evaluating the mass transfer coefficient of a fermentation system in a bubble column.     

Effect of surface contaminants on oxygen transfer in bubble column reactors

Gas hold-up (ɛ_g), sauter mean bubble diameter (d₃₂) and oxygen transfer coefficient (k_La) were evaluated at four different alkane concentrations (0.05, 0.1, 0.3 and 0.5 vol.%) in water over the range of superficial gas velocity (u_g) of (1.18–23.52) × 10⁻³ m/s at 25 °C in a laboratory-scale bubble column bioreactor. Immiscible hydrocarbons (n-decane, n-tridecane and n-hexadecane) were utilized in the experiments as impurity. A type of anionic surfactant was also employed in order to investigate the effect of addition of surfactant to organic-aqueous systems on sauter mean bubble diameter, gas hold-up and oxygen transfer coefficient. Influence of addition of alkanes on oxygen transfer coefficient and gas hold-up, was shown to be dependent on the superficial gas velocity. At superficial gas velocity below 0.5 × 10⁻³ m/s, addition of alkane in air–water medium has low influence on oxygen transfer coefficient and also gas hold-up, whereas; at higher gas velocities slight addition of alkane increases oxygen transfer coefficient and also gas hold-up. Increase in concentration of alkane resulted in increase in oxygen transfer coefficient and gas hold-up and roughly decrease in sauter mean bubble diameter, which was attributed to an increase in the coalescence-inhibiting tendency in the presence of surface contaminant molecules. Bubbles tend to become smaller with decreasing surface tension of hydrocarbon, thus, oxygen transfer coefficient increases due to increasing of specific gas–liquid interfacial area (a). Empirical correlations were proposed for evaluating gas hold-up as a function of sauter mean bubble diameter, superficial gas velocity and interfacial surface tension as well as evaluating Sherwood number as a function of Schmidt, Reynolds and Bond numbers.     

Influence of pluronic F68 on oxygen mass transfer

Pluronic F68 is one of the most used shear protecting additives in cell culture cultivations. It is well known from literature that such surface‐active surfactants lower the surface tension at the gas‐liquid interface, which influences the mass transfer. In this study, the effect of Pluronic F68 on oxygen mass transfer in aqueous solutions was examined. Therefore, the gassing in/gassing out method and bubble size measurements were used. At low concentrations of 0.02 g/L, a 50% reduction on mass transfer was observed for all tested spargers and working conditions. An explanation of the observed effects by means of Higbie's penetration or Dankwerts surface renewal theory was applied. It could be demonstrated that the suppressed movement of the bubble surface layer is the main cause for the significant drop down of the k_La‐values. For Pluronic F68 concentrations above 0.1 g/L, it was observed that it comes to changes in bubble appearance and bubble size strongly dependent on the sparger type. By using the bubble size measurement data, it could be shown that only small changes in mass transfer coefficient (k_L) take place above the critical micelle concentration. Further changes on overall mass transfer at higher Pluronic F68 concentrations are mainly based on increasing of gas holdup and, more importantly, by increasing of the surface area available for mass transfer. © 2013 American Institute of Chemical Engineers Biotechnol. Prog., 29:1278–1288, 2013     

Effect of hydrotropes on solubility and mass transfer coefficient of amyl acetate

This paper presents a comprehensive study on the effect of citric acid, sodium benzoate, sodium salicylate and urea (hydrotropes) on the solubility and mass transfer coefficient for the extraction of amyl acetate in water. The influence of a wide range of hydrotrope concentration (0–3.0?mol/l) and different temperatures (303–333?K) on the solubility of amyl acetate has been studied. The influence of different hydrotrope concentrations on the mass transfer coefficients for amyl acetate–water system has been ascertained. Setschenow constant, K_s, a measure of the effectiveness of hydrotrope has been determined for each case. The solubility of amyl acetate increases with increase in hydrotrope concentration and also with system temperature. Consequent to the increase in the solubility of amyl acetate, the mass transfer coefficient was also found to increase with increase in hydrotrope concentration. A Minimum Hydrotropic Concentration (MHC) was found essential to show a significant increase in the solubility and mass transfer coefficient for amyl acetate–water system. The enhancement factor, which is the ratio of value in presence and absence of a hydrotrope is reported for both solubility and mass transfer coefficients.     

Bubble rise velocities and drag coefficients in non-Newtonian polysaccharide solutions.

Microbially produced polysaccharides have properties which are extremely useful in different applications. Polysaccharide producing fermentations start with liquid broths having Newtonian rheology and end as highly viscous non-Newtonian solutions. Since aerobic microorganisms are used to produce these polysaccharides, it is of great importance to know the mass transfer rate of oxygen from a rising air bubble to the liquid phase, where the microorganisms need the oxygen to grow. One of the most important parameters determining the oxygen transfer rate is the terminal rise velocity of air bubble. The dynamics of the rise of air bubbles in the aqueous solutions of different, mostly microbially produced polysaccharides was studied in this work. Solutions with a wide variety of polysaccharide concentrations and rheological properties were studied. The bubble sizes varied between 0.01 mm3 and 10 cm3. The terminal rise velocities as a function of air bubble volume were studied for 21 different polysaccharide solutions with different rheological properties. It was found that the terminal velocities reached a plateau at higher bubble volumes, and the value of the plateau was nearly constant, between 23 and 27 cm/s, for all solutions studied. The data were analyzed to produce the functional relationship between the drag coefficient and Reynolds number (drag curves). It was found out that all the experimental data obtained from 21 polysaccharide solutions (431 experimental points), can be represented by a new single drag curve. At low values of Reynolds numbers, below 1.0, this curve could be described by the modofoed Hadamard-Rybczynski model, while at Re > 60 the drag coefficient was a constant, equal to 0.95. The latter finding is similar to that observed for bubble rise in Newtonian liquids which was explained on the basis of the "solid bubble" approach.     

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.     

Bubble coalescence behaviour in biological media

Summary Volumetric mass transfer coefficients (k_La) were measured by a steady state method in a twin bubble column to characterize the coalescence behaviour of the medium. Employing Hansenula polymorpha cultivation broths, k_La values were compared with those measured in model media in the presence and absence of antifoam agents. The ratio of the volumetric mass transfer coefficient in the system investigated to that in water, , was employed to characterize the cultivation medium.Symbols a Specific gas/liquid interfacial area with regard to the liquid volume in reactor - d_e Dynamical equilibrium bubble diameter - d_H Perforated plate hole diameter - d_p Primary bubble diameter - d_S Sauter bubble diameter - F_v Liquid feed rate - H Bubbling layer height - k_L Gas/liquid mass transfer coefficient - k_La Volumetric mass transfer coefficient - m k_La/(k_La)_r coalescence index - m_corr Corrected coalescence index [Eq. (3)] - OTR Oxygen transfer rate - P_O Dissolved O₂-partial pressure in BS2 - P₁ Dissolved O₂-partial pressure in BS1 - P_O P_O/P_S relative oxygen saturation in BS2 - P₁ P₁/P_S relative oxygen saturation in BS1 - P_S Saturation dissolved oxygen partial pressure - R_c dn_B/dt coalescence rate - S Substrate concentration - t_F Time since the beginning of the cultivation - X Biomass concentration - V₁ Liquid volume in BS1 - w_SG Superficial gas velocity in BS1 - G Gas holdup in BS1 - ₁ V₁/F_v mean liquid residence time in BS1 - BS1 O₂ absorber column - BS2 O₂ desorber column - D Desmophen (antifoam agent) - NS Nutrient salt solution (Table 1)     

Liquid-phase mass transfer coefficients in bioreactors

Liquid-phase mass transfer coefficient in bioreactors have been examined. A theoretical model based on the surface renewal concept has been devloped. The predicted liquid-phase mass transfer coefficients are compared with the experimental data for a mycelial fermentation broth (Chaetomium cellulolyticum) and model media (carboxymethyl cellulose) in a bench-scale bubble column reactor. The liquid-phase mass transfer coefficient is evaluated by dividing the volumetric mass transfer coefficient obtained experimentally by the specific surface area estimated using the available correlations. The available literature data in bubble column and stirred tank bioreactors is also used to test the validity of the proposed model. A reasonable agreement between the model and the experimental data is found.     

Cultivation of Hansenula polymorpha in tower loop reactors

Summary Hansenula polymorpha was cultured for extended periods in an air lift tower loop reactor (15 cm in diameter with a 275 cm bubbling layer height) with ethanol and/or glucose as the substrates. At constant operation conditions variations of the following parameters were measured: the consumption of the substrate and oxygen, the production of CO₂ and biomass, the longitudinal concentration profile of dissolved oxygen, the oxygen and substrate yield coefficients, the respiratory quotient and the specific interfacial area and volumetric mass transfer coefficient. The influence of the microorganisms on the oxygen transfer rate is discussed especially in the case of glucose repression.     

Combined effect of hydrodynamic and interfacial flow parameters on lysozyme deactivation in a stirred tank bioreactor

The dynamic environment within a bioreactor and in the purification equipment is known to affect the activity and yield of enzyme production. The present research focuses on the effect of hydrodynamic flow parameters (average energy dissipation rate, maximum energy dissipation rate, average shear rate, and average normal stress) and the interfacial flow parameters (specific interfacial area and mass transfer coefficient) on the activity of lysozyme. Flow parameters were estimated using CFD simulation based on the k-epsilon approach. Enzyme deactivation was investigated in 0.1, 0.3, 0.57, and 1 m i.d. vessels. Enzyme solution was subjected to hydrodynamic stress using various types of impellers and impeller combinations over a wide range of power consumption (0.03 < P(G)/V < 7, kW/m3). The effects of tank diameter, impeller diameter, blade width, blade angle, and the number of blades on the extent of deactivation were investigated. At equal value of P(G)/V, epsilon(max), and gamma(avg), the extent of deactivation was dramatically different for different impeller types. The extent of deactivation was found to correlate well with the average turbulent normal stress and the mass transfer coefficient.     

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.     

Generation of small bubbles and small bubble-liquid mass transfer in airlift reactors containing highly viscous liquids

The time-dependent gas hold-up is investigated during the aeration of the Saccharomyces cerevisiae suspension, the aqueous saccharose solutions and the glycerol solutions in the external loop airlift reactor. Due to the time-dependent bubble size distribution the fraction of the small bubble hold-up in the total gas hold-up decreases with an increase of the gas flow rate and with a decrease of the viscosity. The course of the accumulation process of the small bubbles is described by the first-order kinetic equation. The small bubble accumulation rate is investigated in the airlift reactor and the bubble column. It is showed that the small bubbles form and disappear exclusively in the riser of the airlift reactor. It is found that the small bubble-liquid mass transfer coefficient is several times larger than the overall oxygen transfer coefficient.     

Bubble coalescence behaviour in biological media

Summary A twin bubble column was used to measure the k_La values for oxygen in model and cultivation media using the steady state method described previously (Adler et al. 1980). Desmophen and soy oil were used as antifoam agents together with model and/or cultivation media for Chaetomium cellulotyticum, Trichoderma reesei, Hansenula polymorpha, Saccharomyces cerevisiae and Escherichia coli. The bubble coalescence behavior is mainly influenced by antifoam agents and somewhat by protein and alcohol additives. In the range investigated (0.01 to 0.1%.), the k_La values are not influenced by the Desmophen concentration and only slighthly by the soy oil concentration (0.5 to 1.5%.). The coalescence behaviour was characterized by the ratio m_corr=(k_La)_corr/(k_La)_ref. A nutrient salt solution with Desmophen was used as a reference. The k_La measured in the investigated media were corrected by considering the differences in k_La's in the investigated and reference media. These m_corr values can directly be used for bubble columns close to the optimum aeration rate.Symbols a Specific gas/liquid interfacial area - c Concentration - k_L Mass transfer coefficient - k_La Volumetric mass transfer coefficient - W_SG Superficial gas velocity - E_G Relative gas hold-up     

Influence of the tumor mass on the valine rate constants and on valine incorporation into proteins in an experimental brain tumor model

Quantitative autoradiography was used to estimate regional transfer coefficients for valine incorporation and the rate of valine (exogenous and total) incorporation into proteins in an implanted brain-tumor model (AA ascites tumor). Special attention was paid to the evaluation of the tumor mass influence on the transfer coefficients and the rate of incorporation. The size of the tumors used in this study ranged from 2 to 5 mm in diameter. Nine groups of two to three animals each were used to determine the transfer coefficient. The transfer coefficients for movement of the label between different compartments were significantly greater in the tumor than in the normal brain. There is no tumor mass effect on the transfer coefficients or the rate of valine incorporation into proteins in surrounding or remote brain structures. The ratio between specific radioactivities of the free valine in tissue and plasma was also measured. Results indicate that approximately the same fraction of the total valine is recycled in cortex as in the tumor tissue. The mean rates of exogenous valine incorporation into proteins (nmol g⁻¹ min⁻¹) is about one order of magnitude greater in the tumor than in the contralateral parietal cortex.     

Influence of antifoam agents on gas hold-up and mass transfer in bubble columns with non-newtonian fluids

Summary Experimental studies on the effect of antifoam agents on the performance of bubble columns with non-Newtonian fluids have been conducted. It is found that the gas hold-up and volumetric mass transfer coefficient in the case of water were reduced due to the addition of antifoam agents. It was found that this decrease in volumetric mass trasfer coefficient is substantial but in the aqueous solutions of polymers the effect becomes weaker as the concentration of polymers becomes higher. When the concentration of polymers became higher than a certain value, the volumetric mass transfer coefficient in the aqueous solutions of polymers with antifoam agents was higher than that without antifoam agents.Nomenclature a Specific surface area, 1/m - D _c Column diameter, m - d _max Diameter of the largest bubble stable against breakup, m - d _min Diameter of the smallest bubble stable against coalescence, m - g Gravitational acceleration, m/s² - H _l Clear liquid height, m - h Rupture thickness of the liquid film, m - K Consistency index in a power-law model, Pa·s ⁿ - k _l Liquid-phase mass transfer coefficient, m/s - n Flow index in a power-law model - u _sg Superficial gas velocity, m/s Greek letters Shear rate, 1/s - Gas hold-up - Energy dissipation per unit mass, m²/s³ - Viscosity, Pa·s - p Density, kg/m³ - Surface tension, N/m - Shear stress-Pa