Influence of impeller type on power input in fermentation vessels

Prior investigations comparing radial flow Rushton impellers with axial flow hydrofoil impellers (Maxflo T and A315) were extended at the pilot scale. Six types of impellers (disk-style Rushton, Prochem Maxflo T hydrofoils of three diameters pumping downwards and A315 hydrofoils pumping upwards and downwards) were compared for qualitative differences in power number behavior with Reynolds' number, single versus double impeller power draw, gassed power reduction with aeration number and gas hold-up. Power measurements were obtained using watt transducers which, although limited in accuracy and prone to interferences, were able to provide useful qualitative monitoring results. Measurements were conducted using three model liquid systems: water, glycerol and Melojel (soluble starch). Apparent viscosities for actual Streptomyces cultivations were estimated using measured gassed power values and the experimental relationships obtained for gassed/ungassed power to aeration number and power number to Reynolds' number for the glycerol model system. Results confirmed the lower power number and lower shear environment for hydrofoil impellers, yet suggested useful trends for various process parameters and process fluids.     

Dimensionless criteria for estimating oxygen transfer in aeration systems

The effect of power consumption on oxygen transfer efficiency has been evaluated for both surface and subsurface aeration systems. Two new dimensionless criteria (numbers) have been proposed for this purpose. They are termed the efficiency criterion or T(o) number and the power consumption effect criterion or Av number. The analysis presented in this article is based on data obtained on various full-scale aeration systems, and it shows that for each aerator there is an optimum power consumption at which maximum oxygen transfer efficiency results. The oxygen transfer efficiency has maximum values when the efficiency criterion (T(o) number) reaches an approximately constant value. The results have proven that when there are several aerators with identical diameters and the same rotational velocity but different geometrical shapes, the most efficient one will be (after having reached the maximum transfer efficiency) the one with the highest power consumption. For two aerators varying in diameter but with the same parameter as above (maximum transfer, equal rotational velocity), different efficiencies are obtained, the difference being a function of d(-0.5). The results of investigating subsurface aeration systems show that the efficiency of decreased.     

kLa of stirred tank bioreactors revisited

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

A fluid dynamic study of the retrofitting of large agitated bioreactors: Turbulent flow

Studies were conducted in three 19-m(3) fermentors (14 m(3) working volume, aspect ratio = 3:1), one fitted with four Rushton turbines (D/T = 0.35), one with three Lightnin' A315 hydrofoil impellers (D/T = 0.46). The power drawn under the same aerated conditions relative to the unaerated ones was always greater with the hydrofoils, which gives them the potential for enhanced mass transfer rates under practical operating conditions. However, the power draw was also sensitive to the magnitude of the unaerated power. Indeed, at low unaerated specific power ( approximately 0.6 W-kg) and high air flow rates ( approximately 1vvm), the relative power draw with the hydrofoils could be even greater than 1. The hold-up with each of the impellers was broadly similar at the same aeration rate and power input, though the later had a much smaller impact in these large vessels than has been reported in the literature based on smaller scale work. As usual, repressed coalescence caused increased hold-up, and, with the hydrofoils, this increase was associated with a lower power draw. Because of the greater mechanical vibration of the reactors with the hydrofoils, vibration characteristics of the vessels were measured and they were very similar. The results showed that provided care is taken in the mechanical design of the system, such impellers can operate reliably in large-scale fermentations with the potential for enhanced biological performance. (c) 1994 John Wiley & Sons, Inc.     

Triarylmethane Dye Decolorization by Pellets of Pycnoporus sanguineus: Statistical Optimization and Effects of Novel Impeller Geometry

A study was carried out to optimize selected parameters for decolorization of a triarylmethane dye, such as crystal violet by white rot fungus, Pycnoporus sanguineus, pellets. The parameters studied were initial dye concentration (ppm), agitation speed (rpm), and process time (days) and were optimized using response surface methodology (RSM). It is shown that process time, agitation speed, and their interactions have significant effects on the decolorization process. Following the optimization, the decolorization study was extended to a stirred tank reactor (STR) process. Effects of different geometry of impellers on the decolorization process and power consumption were studied. Novel impeller geometries, such as 180° curved blade and 60° angled blade impellers, were used in the STR. The application of 180° curved blade impeller resulted in higher percentage of decolorization at a relatively less power consumption as compared with 60° angled blade impeller.     

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.     

The use of flow cytometry to study the impact of fluid mechanical stress on Escherichia coli W3110 during continuous cultivation in an agitated bioreactor

Continuous culture fermentations of Escherichia coli W3110 have been carried out at controlled dissolved oxygen levels of 40% and 10% of saturation. Satisfactory and reproducible results were obtained. Agitation speeds of 400 and 1200 rpm at an aeration rate of 1 vvm have been used as well as an aeration rate of 3 vvm at 400 rpm. The upper levels of these variables represent much higher agitation and aeration intensities than those normally used in practical fermentations. The fermentations were monitored by mass spectrometry and optical density, and cell samples were studied by flow cytometry, SEM, and TEM. Protocols were developed so the state of both cell membranes and cell size could be measured by flow cytometry. Under all the conditions of agitation and aeration, flow cytometric analysis indicated that both cell membranes were intact and that a cytoplasmic membrane potential existed; also the cell size did not change, results confirmed by SEM and TEM. There were no detectable changes in off-gas analysis or optical density during the continuous fermentation nor in the cell structure as revealed by SEM or TEM, except at the highest agitation intensity. Under the latter conditions, after 7 h, the outer polysaccharide layer on the cell was stripped away. It is concluded that any changes in biological performance of this E. coli cell line due to variations in agitation or aeration intensity or scale of operation cannot be attributed to fluid dynamic stresses associated with the turbulence generated by impellers or with bursting bubbles.     

Power consumption of agitated gas-liquid-solid systems with particular relevance to solid substrate submerged culture fermentations

Summary The Michel and Miller (1962) equation is routinely used to estimate the effect of aeration on power consumption in submerged culture fermentation systems. However this correlation was developed for systems that do not contain solid substrates. Since many industrial fermentations use solid substrates, this study developed a modification of the Michel and Miller equation that can be used to predict power consumption when solid substrates are present. A correlation relating power to solids addition was established by adding bran and apple pomace to water, and measuring the power drawn by four separate impeller configurations.This correlation applies to solids content up to 16.7% w/w and bulk densities between 1020 to 1210 kg/m³. It was found that when aerated the power consumption decreased upon addition of solid substrate. The most likely explanation of this behaviour is that initially the gas hold up increased, decreasing power consumption. At high solid loadings, the power decrease was up to 30% (compared to 66% decrease in power caused by high aeration rates).     

Influence of aeration intensity on mature aerobic granules in sequencing batch reactor

Aeration intensity is well known as an important factor in the formation of aerobic granules. In this research, two identical lab-scale sequencing batch reactors with aeration intensity of 0.8 (R1) and 0.2 m³/h (R2) were operated to investigate the characteristics and kinetics of matured aerobic granules. Results showed that both aeration intensity conditions induced granulation, but they showed different effects on the characteristics of aerobic granules. Compared with the low aeration intensity (R2), the aerobic granules under the higher aeration intensity (R1) had better physical characteristics and settling ability. However, the observed biomass yield (Y _obs) in R1 [0.673 kg mixed liquor volatile suspended solids (MLVSS)/kg chemical oxygen demand (COD)] was lower than R2 (0.749 kg MLVSS/kg COD). In addition, the maximum specific COD removal rates (q _max) and apparent half rate constant (K) of mature aerobic granular sludge under the two aeration intensities were at a similar level. Therefore, the matured aerobic granule system does not require to be operated in a higher aeration intensity, which will reduce the energy consumption.     

Shear stress effects on cell growth and <Emphasis Type="SmallCaps">L</Emphasis>-DOPA production by suspension culture of <Emphasis Type="Italic">Stizolobium hassjoo</Emphasis> cells in an agitated bioreactor

Suspension cultures of Stizolobium hassjoo cells were cultivated in a 7l bioreactor. The growth rate and intracellular L-DOPA content of the cells using two different turbine impellers were compared. There were distinct differences in growth behavior and L-DOPA productivity in the range of 100 to 500 rpm for flat-blade turbine impeller. Disk turbine retarded significantly the cell growth but not so significantly for L-DOPA production in the range of 200 to 300 rpm. The shear force intensity of the two impellers at various rotational rates was compared with shear force index (SFI), and power input per unit mass and eddy length scale. There was good consistency among the three indexes for shear force intensity. Thus with SFI the shear force intensity of bioreactor can be indirectly estimated. A critical shear stress that may cause sublytic effect in cells was identified for flat-blade turbine operated at 400 rpm. The common effect between the shear stress and the proton elicitation in the bioreactor was elucidated with a hypothesis of signal transduction by second messenger, H⁺. Our results suggested that H⁺ transduced the signal to protoplast when S. hassjoo cells were stimulated by shear stress. This resulted in an increase of H⁺ which triggered a similar reaction to the pH control of culture broth and enhanced the L-DOPA production.     

Nitrogen compounds in wine during its biological aging by two flor film yeasts: An approach to accelerated biological aging of dry sherry-type wines

Urea, ammonium, and free amino acid contents were quantified in biological aging of a young wine under two flor film forming yeast strains, Saccharomyces cerevisiae race capensis and S. cerevisiae race bayanus, and compared. Cell viability in the film was different for the two yeast strains. Thus, capensis maintained a much greater number of viable cells per surface area than bayanus and hence used greater amount of nitrogen compounds. The main source of nitrogen for the yeasts during the biological aging process was L-proline. The two yeast strains also differed in the amounts of assimilable nitrogen they utilized, in their preferences for amino acid consumption, and kinetics. To accelerate the aging process, the effect of controlled monthly aeration of the wine aged with capensis strain was investigated. The results revealed that short aeration did not appreciably increase the overall consumption of assimilable nitrogen, but consumption of some nitrogen compounds was accelerated (particularly L-proline, L-tryptophan, L-glutamic acid, ammonium ion, L-lysine, and L-arginine); the use of L-ornithine was inhibited; and GABA, L-methionine, and urea were depletes. Probably the aeration increases the aroma compounds, thereby producing wines with improved sensory properties. (c) 1997 John Wiley & Sons, Inc.     

Effect of sludge flocs on the aeration performance of suction-impellers

The authors have investigated a special aspect of the transfer of oxygen: the aeration performance of small-scale suction-impellers in a suspension of activated sludge floes and a performance comparison with clear water. The principle of the impellers is, that in order to disperse air bubbles into the aforementioned liquids, all that we need do is a simple stirring. Due to the impellers the authors could not show a reduction of the oxygen transfer coefficient in the presence of sludge flocs. Former comparative studies of oxygen transfer, using a fixed orifice, did show a reduction in the presence of sludge flocs. Therefore, it seems probable that the effect of activated sludge flocs on the transfer coefficient is linked with the manner in which air is dispersed, i.e., depends on whether an orifice is fixed or moved. The experimental results allow presumption that by developing a high intensity of shear near the location where air bubbles are produced, we are able to minimize the effect of sludge flocs on the process of bubble formation.     

Effect of conditions of agitation and aeration on the biosynthesis of oleandomycin

The data on the effect of the aeration and agitation conditions on biosynthesis of oleandomycin in 0.75, 3 and 50 m3 apparatus are presented. The relationship between the biosynthetic parameters, oxygen dissolution rate and specific power consumption for agitation was studied. It was shown that the values of the specific power consumption for agitation were not acceptable for scaling up the process of oleandomycin biosynthesis.     

New milliliter‐scale stirred tank bioreactors for the cultivation of mycelium forming microorganisms

A novel milliliter‐scale stirred tank bioreactor was developed for the cultivation of mycelium forming microorganisms on a 10 milliliter‐scale. A newly designed one‐sided paddle impeller is driven magnetically and rotates freely on an axis in an unbaffled reaction vessel made of polystyrene. A rotating lamella is formed which spreads out along the reactor wall. Thus an enhanced surface‐to‐volume ratio of the liquid phase is generated where oxygen is introduced via surface aeration. Volumetric oxygen transfer coefficients (k_La) > 0.15 s^?1 were measured. The fast moving liquid lamella efficiently prevents wall growth and foaming. Mean power consumption and maximum local energy dissipation were measured as function of operating conditions in the milliliter‐scale stirred tank bioreactor (V = 10 mL) and compared to a standard laboratory‐scale stirred tank bioreactor with six‐bladed Rushton turbines (V = 2,000 mL). Mean power consumption increases with increasing impeller speed and shows the same characteristics and values on both scales. The maximum local energy dissipation of the milliliter‐scale stirred tank bioreactor was reduced compared to the laboratory‐scale at the same mean volumetric power input. Hence the milliliter impeller distributes power more uniformly in the reaction medium. Based on these data a reliable and robust scale‐up of fermentation processes is possible. This was demonstrated with the cultivation of the actinomycete Streptomyces tendae on both scales. It was shown that the process performances were equivalent with regard to biomass concentration, mannitol consumption and production of the pharmaceutical relevant fungicide nikkomycin Z up to a process time of 120 h. A high parallel reproducibility was observed on the milliliter‐scale (standard deviation < 8%) with up to 48 stirred tank bioreactors operated in a magnetic inductive drive. Rheological behavior of the culture broth was measured and showed a highly viscous shear‐thinning non‐Newtonian behavior. The newly developed one‐sided paddle impellers operated in unbaffled reactors on a 10 milliliter‐scale with a magnetic inductive drive for up to 48 parallel bioreactors allows for the first time the parallel bioprocess development with mycelium forming microorganisms. This is especially important since these kinds of cultivations normally exhibit process times of 100 h and more. Thus the operation of parallel stirred tank reactors will have the potential to reduce process development times drastically. Biotechnol. Bioeng. 2010; 106: 443–451. © 2010 Wiley Periodicals, Inc.     

A novel centrifugal impeller bioreactor. II. Oxygen transfer and power consumption

The effects of the impeller configuration, aeration rate, and agitation speed on oxygen transfer coefficient K(L)a were studied in a newly designed centrifugal impeller bioreactor (5-L). The oxygen transfer rates in the novel bioreactor were also compared with those in a cell-lift bioreactor with comparable dimensions. The cell-lift impeller produced much higher surface oxygen transfer rates than the centrifugal one at an agitation speed over 200 rpm. This result was in good agreement with our observation that the cell-lift impeller produced much higher unfavorable turbulence. In addition, the experiments using granulated agar particles as pseudo plant cells indicated that the K(L)a value decreased steadily with an increase in agar particle concentration, and the centrifugal impeller still demonstrated a larger K(L)a than the cell lift up to a high pseudo cell concentration of 19.5 g dry weight (DW)/L (under 150 rpm and 0.20 vvm) or 22.3 g DW/L (under 200 rpm and 0.20 vvm). Furthermore, the correlation between power number and impeller Reynolds number for both the centrifugal and the cell-lift impellers was successfully obtained, which could be used for predicting the power input required by each impeller. From the results obtained, the centrifugal impeller bioreactor is expected to have great potential in its application to shear-sensitive biological systems.     

Pellet morphology, culture rheology and lovastatin production in cultures of Aspergillus terreus

Pellet growth of Aspergillus terreus ATCC 20542 in submerged batch fermentations in stirred bioreactors was used to examine the effects of agitation (impeller tip speed u(t) of 1.01-2.71 ms(-1)) and aeration regimens (air or an oxygen-enriched mixture containing 80% oxygen and 20% nitrogen by volume) on the fungal pellet morphology, broth rheology and lovastatin production. The agitation speed and aeration methods used did not affect the biomass production profiles, but significantly influenced pellet morphology, broth rheology and the lovastatin titers. Pellets of approximately 1200 microm initial diameter were reduced to a final stable size of approximately 900 microm when the agitation intensity was >/=600 rpm (u(t)>/=2.03 ms(-1)). A stable pellet diameter of approximately 2500 microm could be attained in less intensely agitated cultures. These large fluffy pellets produced high lovastatin titers when aerated with oxygen-enriched gas but not with air. Much smaller pellets obtained under highly agitated conditions did not attain high lovastatin productivity even in an oxygen-enriched atmosphere. This suggests that both an upper limit on agitation intensity and a high level of dissolved oxygen are essential for attaining high titers of lovastatin. Pellet size in the bioreactor correlated equally well with the specific energy dissipation rate and the energy dissipation circulation function. The latter took into account the frequency of passage of the pellets through the high shear regions of the impellers. Pellets that gave high lovastatin titers produced highly shear thinning cultivation broths.     

Surface aeration in a small,agitated, and sparged vessel

In a recent publication, a technique was outlined for measuring surface aeration rates in an agitated vessels while sparging, and it was shown that surface aeration rates fall rapidly with increasing sparge rates. That work was conducted in a 0.61 m diam vessels. The work reported here was done in a small vessel (0.22 m diam) where surface aeration has been reported to be of particular significance. In general, the results obtained in the small vessel confirmed those in the large one and in addition were generally in good agreement with those recently published elsewhere for an almost identical geometry. For typical practical power inputs and sparge rates, the rate of surface aeration was never more than 20% of the sparge rate and generally less than 5%. These results indicate that surface aeration is of considerably less importance than has generally been believed following the findings of workers who estimated its effect by comparing KL a values under unsparged conditions with those when sparging.     

Studies on transfer processes in mixing vessels: effect of particles on gas-liquid hydrodynamics using modified Rushton turbine agitators

The work presents the effect of solid particles having a mean diameter between 15–1000?μm, on the gas dispersion in a mechanically agitated vessel with standard and modified Rushton turbine agitators positioned singly or doubly on same shaft. For the dispersing and uniform distribution of the three phase (gas-liquid-solid) through the entire vessel section, the modified blade turbines, with the surface fraction of the perforations equal to 0.353, were found to be more efficient, the power consumption being reduced by approximately 50%in comparison with the standard Rushton turbines. The power number in the turbulent mixing of the three phase system is dependent on the aeration rate, the surface fraction of the perforations, the turbine number and the physical and rheological properties of the suspensions.     

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.     

Design of a large-scale surface-aerated bioreactor for biomass production using a VOC substrate

The design of a large-scale bioreactor for the production of bacterial biomass adapted to the biodegradation of volatile organic compounds was carried out. The bioreactor model used integrated the microbial kinetics and fluid dynamics described by the compartment model approach. The process conditions and kinetic parameters were adopted from the laboratory experimental study of (León, E., Seignez, C., Adler, N., Péringer, P., 1999. Growth inhibition of biomass adapted to the degradation of toluene and xylenes in mixture in a batch reactor with substrates supplied by pulses. Biodegradation 10, 245-250). The performance of the pulsed-batch stirred bioreactor under surface aeration conditions was simulated for different mixing configurations and conditions such as the impeller diameter, number of impellers, stirring speed, and oxygen pressure. The simulations were used for the cost analysis which resulted in the optimal design of the bioreactor.