Studies on mass transfer characteristics of a modified airlift fermenter

An approach to modify external loop airlift bioreactor is presented that examines its performance with respect to mass transfer. There are various designs of airlift fermenter [1]. In the proposed system [2] the riser has been replaced by a tube of irregular geometry, in the form of converging-diverging sections (CDT-ALF), so that better mass transfer may be obtained due to better liquid mixing caused by the bubble flow, pulsation effect and early transition to turbulence. Mass transfer characteristics of the modified airlift fermenter CDT-ALF were studied and compared with those of a conventional one, UT-ALF. Overall volumetric mass transfer coefficient,K _L a, was determined by sulfite oxidation method.K _L a was determined with respect toU _G for differenth _i. HigherK _L a was always observed in CDT-ALF compared to that in UT-ALF under any operating condition ofh _i andU _G. If theK _L a values are compared in both the systems under their optimum conditions ofh _i andU _G, CDT-ALF showed 122.5% higher values ofK _L a compared to UT-ALF. However, when both the systems were operated at the lowest experimental conditions ofU _G, thek _L a in CDT-ALF was found to be 170% higher. In UT-ALF while with the decrease ofU _G,k _L a decreased, in CDT-ALF the reverse was observed i.e. at lowU _G,K _L a was higher. However with the increase ofh _i,K _L a decreased in both the systems. To predict volumetric mass transfer coefficientK _L a, empirical correlations were developed by dimensional analysis for both the reactors. The correlations were experimentally verified to determine their reliability to predict mass transfer coefficient and the deviation was found within reasonable limit.List of abbreviations ALF Airlift Fermenter - UT-ALF Uniform Tube Airlift Fermenter - CDT-ALF Converging-diverging Tube Airlift Fermenter     

Hydrodynamic characteristics and gas-liquid mass transfer in a biofilm airlift suspension reactor

The hydrodynamics and mass transfer, specifically the effects of gas velocity and the presence and type of solids on the gas hold-up and volumetric mass transfer coefficient, were studied on a lab-scale airlift reactor with internal draft tube. Basalt particles and biofilm-coated particles were used as solid phase. Three distinct flow regimes were observed with increasing gas flow rate. The influence of the solid phase on the hydrodynamics was a peculiar characteristic of the regimes. The volumetric mass transfer coefficient was found to decrease with increasing solid loading and particle size. This could be predominantly related to the influence that the solid has on gas hold-up. The ratio between gas hold-up and volumetric mass transfer coefficient was found to be independent of solid loading, size, or density, and it was proven that the presence of solids in airlift reactors lowers the number of gas bubbles without changing their size. To evaluate scale effects, experimental results were compared with theoretical and empirical models proposed for similar systems.     

Influence of sparger on energy dissipation, shear rate, and mass transfer to sea water in a concentric-tube airlift bioreactor

Data on volumetric mass-transfer coefficient, K_La_L, in a 12 × 10⁻³ m³ airlift bioreactor are reported. Measurements were made in sea water. The superficial gas velocity ranged up to 0.21 m/s. Four cylindrical spargers (60–1000 μm pore size) were tested. In bubbly flow, the sparger pore size strongly influenced the K_La_L; the highest K_La_L values were obtained with the smallest pore size. In contrast, in the transition and heterogeneous flow regimes, the pore size had little influence on K_La_L. The best correlation of the mass transfer data was obtained when both gas holdup and liquid superficial velocity were taken as independent variables. Shear rates were estimated in the different zones of the reactor. The highest values were found in the bottom zone of the reactor and in the gas-liquid separator. The penetration and isotropic turbulence models were used to develop a semi-theoretical equation relating the volumetric mass-transfer coefficient to shear rate; hence providing a better understanding of how the operational variables may be manipulated to attain a moderate shear rate and an appropriate level of mass transfer, two extremely important parameters for the growth of sensible microorganisms as those used in marine biotechnology.     

Saccharomyces cerevisiae fermentations in a pilot scale airlift bioreactor: Comparison of air sparger configurations

Hydrodynamic and oxygen transfer comparisons were made between two ring sparger locations, draft tube and annulus, in a concentric pilot scale airlift reactor with a baker's yeast suspension. Sectional hydrodynamic measurements were made and a mobile DOT probe was used to characterise the oxygen transfer performance through the individual sections of the reactor. The hydrodynamic performance of the reactor was improved by using a draft tube ring sparger rather than the annulus ring sparger. This was due to the influence of the ratio of the cross sectional area of the downcomer and riser (A _D/A_R) in conjunction with the effect of liquid velocity and a parameter,C ₀, describing the distribution of the liquid velocity and gas holdup across the riser on the bubble coalescence rates. The mixing performance of the reactor was dominated by the frequency of the passage of the broth through the end sections of the reactor. An optimum liquid height above the draft tube, for liquid mixing was demonstrated, above which no further improvement in mixing occurred. The liquid velocity and degree of gas entrainment showed little dependency on top section size for both sparger configurations. Extreme dissolved oxygen heterogeneity was demonstrated around the vessel with both sparger configurations and was shown to be detrimental to the oxygen uptake rate of the baker's yeast. Dissolved oxygen tensions below 1% air saturation occurred along the length of the riser and then rose in the downcomer. The greater oxygen transfer rate in the downcomer than in the riser was caused by the combined effects of a larger slip velocity in the downcomer which enhancedk _La and gas residence time, high downcomer gas holdup, and the change in bubble size distribution between the riser and downcomer. The position of greatest oxygen transfer rate in the downcomer was shown to be affected by the reactor from the influence on downcomer liquid linear velocity. UCL is the Biotechnology and Biological Sciences Research Council sponsored Advanced Centre for Biochemical Engineering and the Council's support is greatly acknowledged.     

Hydrodynamics and mass transfer in a tubular airlift photobioreactor

In photobioreactors, which are usually operated under light limitation,sufficient dissolved inorganic carbon must be provided to avoid carbonlimitation. Efficient mass transfer of CO₂ into the culture mediumisdesirable since undissolved CO₂ is lost by outgassing. Mass transferof O₂ out of the system is also an important consideration, due tothe need to remove photosynthetically-derived O₂ before it reachesinhibitory concentrations. Hydrodynamics (mixing characteristics) are afunctionof reactor geometry and operating conditions (e.g. gas and liquid flow rates),and are a principal determinant of the light regime experienced by the culture.This in turn affects photosynthetic efficiency, productivity, and cellcomposition. This paper describes the mass transfer and hydrodynamics within anear-horizontal tubular photobioreactor. The volume, shape and velocity ofbubbles, gas hold-up, liquid velocity, slip velocity, axial dispersion,Reynoldsnumber, mixing time, and mass transfer coefficients were determined intapwater,seawater, and algal culture medium. Gas hold-up values resembled those ofvertical bubble columns, and the hydraulic regime could be characterized asplug-flow with medium dispersion. The maximum oxygen mass transfer coefficientis approximately 7 h^–1. A regime analysisindicated that there are mass transfer limitations in this type ofphotobioreactor. A methodology is described to determine the mass transfercoefficients for O₂ stripping and CO₂ dissolution whichwould be required to achieve a desired biomass productivity. This procedure canassist in determining design modifications to achieve the desired mass transfercoefficient.     

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.     

Gas holdup and mass transfer characteristics of carboxymethyl cellulose solutions in a bubble column with a radial gas sparger

The gas phase holdup and mass transfer characteristics of carboxymethyl cellulose (CMC) solutions in a bubble column having a radial gas sparger have been determined and a new flow regime map has been proposed. The gas holdup increases with gas velocity in the bubbly flow regime, decreases in the churn-turbulent flow regime, and increases again in the slug flow regime. The volumetric mass transfer coefficient (k _La) significantly decreases with increasing liquid viscosity. The gas holdup and k _La values in the present bubble column of CMC solutions are found to be much higher than those in bubble columns or external-loop airlift columns with a plate-type sparger. The obtained gas phase holdup ( _g) and k _La data have been correlated with pertinent dimensionless groups in both the bubbly and the churn-turbulent flow regimes.List of Symbols a m^–1 specific gas-liquid interfacial area per total volume - A _d m² cross-sectional area of downcomer - A _r m² cross-sectional area of riser - d _b m individual bubble diameter - d _vs m Sauter mean bubble diameter - D _c m column diameter - D _L m²/s oxygen diffusivity in the liquid - Fr Froude number, U _g/(g D_c)^1/2 - g m/s² gravitational acceleration - G _a Galileo number, gD _c ^{3 2}/² _app - H _a m aerated liquid height - H _c m unaerated liquid height - K Pa · sⁿ fluid consistency index - k _L a s^–1 volumetric mass transfer coefficient - n flow behavior index - N _i number of bubbles having diameter d _bi - Sc Schmidt number, _app/( D _L) - Sh Sherwood number, k _L a D _c ² /D_L - U _sg m/s superficial gas velocity - U _gr m/s superficial riser gas velocity - V _a m³ aerated liquid volume - V _c m³ unaerated liquid volume - N/m surface tension of the liquid phase - _g gas holdup - _app Pa · s effective viscosity of non-Newtonian liquid - kg/m³ liquid density - ý s^–1 shear rate - Pa shear stress     

Effects of geometrical design on hydrodynamic and mass transfer characteristics of a rectangular-column airlift bioreactor

Gas holdup and gas–liquid mass transfer coefficients were measured in a 21-L rectangular-column airlift bioreactor with aspect ratio of 10 and working volumes ranging from 10 to 16 L. The effect of the bottom and top clearances was investigated using water and mineralized CMC solutions and covering a range of effective viscosity from 0.02 to 0.5 Pa s and surface tension from 0.065 to 0.085 N m⁻¹. The gas holdup and mass transfer results were successfully correlated using expressions derived via dimensional analysis. The separator gas holdup was found to be similar to the total gas holdup in the airlift bioreactor. The downcomer gas holdup (ɛ_d) increased two-fold when the bottom clearance (h_b) was increased from 0.014 to 0.094 m while the top clearance (h_t) had no effect. Increasing h_b decreased the mass transfer by 50% compared to 31% when the top clearance (h_t/D_hr) was increased. It was found that the gas–liquid separator diameter ratio (D_hs/D_hc) exerted the maximal influence of over 65% on mass transfer as compared to both clearances.     

Viscous media in tower bioreactors: Hydrodynamic characteristics and mass transfer properties

Studies in tower reactors with viscous liquids on flow regime, effective shear rate, liquid mixing, gas holdup and gas/ liquid mass transfer (k _La) are reviewed. Additional new data are reported for solutions of glycerol, CMC, PAA, and xanthan in bubble columns with diameters of 0.06, 0.14 and 0.30 m diameter. The wide variation of the flow behaviour index (1 to 0.18) allows to evaluate the effective shear rate due to the gas flow. New dimensionless correlations are developed based on the own and literature data, applied to predict k _La in fermentation broths, and compared to other reactor types.List of Symbols a(a) m^–1 specific interfacial area referred to reactor (liquid) volume - Bo Bond number (g D _c ² _L/) - c _L(c _L ^* ) kmol m^–3 (equilibrium) liquid phase oxygen concentration - C coefficient characterising the velocity profile in liquid slugs - C _s m^–1 coefficient in Eq. (2) - d _B(d_vs) m bubble diameter (Sauter mean of d _B) - d ₀ m diameter of the openings in the gas distributor plate - D _c m column diameter - D _L m²s^–1 diffusivity - E _L(E_W) m² s^–1 dispersion coefficient (in water) - E ² square relative error - Fr Froude number (u _G/(g D_c)^0.5) - g m s^–2 gravity acceleration - Ga Gallilei number (g D _c ³ _L ² / _eff ² ) - h m height above the gas distributor the gas holdup is characteristic for - k Pasⁿ fluid consistency index (Eq. 1) - k _L m s^–1 liquid side mass transfer coefficient - k _La(k_La) s^–1 volumetric mass transfer coefficient referred to reactor (liquid) volume - L m dispersion height - n flow behaviour index (Eq. 1) - P W power input - Re liquid slug Reynolds number ( _L(u _G +u _L) D _c/_eff) - Sc Schmidt number ( _eff/( _L D _L )) - Sh Sherwood number (k _La D _c ² /D_L) - t s time - u _B(u_sw) m s^–1 bubble (swarm) rise velocity - u _G(u_L) m s^–1 superficial gas (liquid) velocity - V(V_L) m³ reactor (liquid) volume Greec Symbols W m^–2 K^–1 heat transfer coefficient - y(y _eff) s^–1 (effective) shear rate - _G relative gas holdup - s relaxation time of viscoelastic liquid - _L(_eff) Pa s (effective) liquid viscosity (Eq. 1) - _L kg m^–3 liquid density - N/m surface tension     

A novel method of simulating oxygen mass transfer in two-phase partitioning bioreactors

An empirical correlation, based on conventional forms, has been developed to represent the oxygen mass transfer coefficient as a function of operating conditions and organic fraction in two-phase, aqueous-organic dispersions. Such dispersions are characteristic of two-phase partitioning bioreactors, which have found increasing application for the biodegradation of toxic substrates. In this work, a critical distinction is made between the oxygen mass transfer coefficient, k(L)a, and the oxygen mass transfer rate. With an increasing organic fraction, the mass transfer coefficient decreases, whereas the oxygen transfer rate is predicted to increase to an optimal value. Use of the correlation assumes that the two-phase dispersion behaves as a single homogeneous phase with physical properties equivalent to the weighted volume-averaged values of the phases. The addition of a second, immiscible liquid phase with a high solubility of oxygen to an aqueous medium increases the oxygen solubility of the system. It is the increase in oxygen solubility that provides the potential for oxygen mass transfer rate enhancement. For the case studied in which n-hexadecane is selected as the second liquid phase, additions of up to 33% organic volume lead to significant increases in oxygen mass transfer rate, with an optimal increase of 58.5% predicted using a 27% organic phase volume. For this system, the predicted oxygen mass transfer enhancements due to organic-phase addition are found to be insensitive to the other operating variables, suggesting that organic-phase addition is always a viable option for oxygen mass transfer rate enhancement.     

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.     

Characterisation of the gas-liquid mass transfer in shaking bioreactors

The maximum gas-liquid mass transfer capacity of 250ml shaking flasks on orbital shaking machines has been experimentally investigated using the sulphite oxidation method under variation of the shaking frequency, shaking diameter, filling volume and viscosity of the medium. The distribution of the liquid within the flask has been modelled by the intersection between the rotational hyperboloid of the liquid and the inner wall of the shaking flask. This model allows for the calculation of the specific exchange area (a), the mass transfer coefficient (k(L)) and the maximum oxygen transfer capacity (OTR(max)) for given operating conditions and requires no fitting parameters. The model agrees well with the experimental results. It was furthermore shown that the liquid film on the flask wall contributes significantly to the specific mass transfer area (a) and to the oxygen transfer rate (OTR).     

Comparison of stirred tank and airlift bioreactors in the production of polygalacturonases by Aspergillus oryzae

The production of endo and exo-polygalacturonase (PG) by Aspergillus oryzae IPT 301 was studied in a stirred tank bioreactor (STR) and an internal circulation airlift bioreactor. Using a factorial experimental design, a soluble culture medium was defined which allowed the production of exo- and endo-PG comparable to that obtained in a medium containing suspended wheat bran. The soluble medium was used in tests to compare the production of these enzymes in the STR and airlift bioreactor. In these tests, after 96 h, maximum enzymatic activity values achieved for exo- and endo-PG were 65.2 units (U) per mL and 91.3 U mL⁻¹, in the STR, with similar activity values of 60.6 U mL⁻¹ and 86.2 U mL⁻¹, respectively, being achieved in the airlift bioreactor. The airlift bioreactor also showed satisfactory results regarding the oxygen transfer rate in this process, indicating its potential to be used in an eventual larger scale production of exo- and endo-PG, with lower costs for both installation and operation.     

Experimental and computational characterization of mass transfer in high turndown bioreactors

Single-use bioreactors (SUBs, or disposable bioreactors) are extensively used for the clinical and commercial production of biologics. Despite widespread application, minimal results have been reported utilizing the turndown ratio; an operation mode where the working range of the bioreactor can be expanded to include low fluid volumes. In this work, a systematic investigation into free surface mass transfer and cell growth in high turndown single-use bioreactors is presented. This approach, which combines experimental mass transfer measurements with numerical simulation, deconvolutes the combined effects of headspace mixing and the free surface convective mass transfer on cell growth. Under optimized conditions, mass transfer across the interface alone may be sufficient to satisfy oxygen demands of the cell culture. Within the context of high turndown bioreactors, this finding provides a counterpoint to traditional sparge-based bioreactor operational philosophy. Multiple monoclonal antibody-producing cell lines grown using this high turndown approach showed similar viable cell densities to those cells expanded using a traditional cell bag rocker. Furthermore, cells taken directly from the turndown expansion and placed into production showed identical growth characteristics to traditionally expanded cultures. Taken together, these results suggest that the Xcellerex SUB can be run at a 5:1 working volume as a seed to itself, with no need for system modifications, potentially simplifying preculture operations.     

Kinetics of biodegradation of p-xylene and naphthalene and oxygen transfer in a novel airlift immobilized bioreactor

The scope of this study included the biodegradation performance and the rate of oxygen transfer in a pilot-scale immobilized soil bioreactor system (ISBR) of 10-L working volume. The ISBR was inoculated with an acclimatized population of contaminant degrading microorganisms. Immobilization of microorganisms on a non-woven polyester textile developed the active biofilm, thereby obtaining biodegradation rates of 81 mg/L x h and 40 mg/L x h for p-xylene and naphthalene, respectively. Monod kinetic model was found to be suitable to correlate the experimental data obtained during the course of batch and continuous operations. Oxygen uptake and transfer rates were determined during the batch biodegradation process. The dynamic gassing-out method was used to determine the oxygen uptake rate (OUR) and volumetric oxygen mass transfer, K(L) a. The maximum volumetric OUR of 255 mg O(2)/L x h occurred approximately at 720-722 h after inoculation, when the dry weight of biomass concentration was 0.67 g/L.     

The influence of geometry on hydrodynamic and mass transfer characteristics in an external airlift reactor for the cultivation of filamentous fungi

The influences of geometric configuration, mycelial broth rheology and superficial gas velocity (U_sg) were investigated with respect to the following hydrodynamic parameters: gas holdup (), oxygen transfer coefficient (K_La) and mixing time (t_m). Increases in U_sg and height of gas separator (H_t) caused an increase in and K_La, and a decrease in t_m. Consequently, a diameter ratio (D_d/D_r) of 0.71 and H_t 0.20 m were found to be the best geometry and operation parameters to achieve high aeration and mixing efficiency for the high viscous broth system in the cultivation of filamentous fungi. An external airlift reactor (EALR) was developed and designed for the cultivation of filamentous fungi. The EALR with two spargers excels in reliability and high aeration and mass transfer coefficiency, resulting in a fast mycelial growth and high biomass productivity in the cultivation of the fungus Rhizopus oryzae.     

Relationships between hydrodynamics and rheology of flocculating yeast suspensions in a high-cell-density airlift bioreactor

In this article a hydrodynamic and rheological analysis of a continuous airlift bioreactor with high-cell-density system is presented. A highly flocculating recombinant strain of Sacharomyces cerevisiae containing genes for lactose transport (lactose permease) and hydrolysis (beta-galactosidase) was exploited to ferment lactose from cheese whey to ethanol. The magnetic particle-tracer method was used to assess the effect of operational conditions (air-flow rate, biomass concentration) on hydrodynamic behavior of an airlift bioreactor during the fermentation process. Measurements of liquid circulation velocity showed the existence of a critical value of biomass concentration at which a dramatic deceleration of net liquid flow appeared with increasing biomass quantity. Rheological analysis revealed exponential increase of viscosity of the yeast floc suspension at the same biomass concentration of about 73 g/dm3 corresponding to 42.8% v/v of solid fraction. These facts have a particular importance for the successful processing of a high-cell-density airlift bioreactor as only a circulated flow regime will be favorable to keep the solid particles in suspension state and evenly distributed throughout the bioreactor.     

Hydrodynamics, mass transfer and rheological studies of gibberellic acid production in an airlift bioreactor

Although a lot of research has been done into modelling microbial processes, the applicability of these concepts to problems specific for bioreactor design and optimization of process conditions is limited. This is partly due to the tendency to separate the two essential factors of bioreactor modelling, i.e. physical transport processes and microbial kinetics. The deficiencies of these models become especially evident in industrial production processes where O₂ supply is likely to become the limiting factor, e.g. production of gibberellic acid and other organic acids. Hydrodynamics, mass transfer and rheology of gibberellic acid production by Gibberella fujikuroi in an airlift bioreactor is presented in this work. Important hydrodynamic parameters such as gas holdup, liquid velocity in the riser and in the downcomer, and mixing time were determined and correlated with superficial gas velocity in the riser. Mass transfer was studied evaluating the volumetric mass transfer coefficient, which was determined as a function of superficial gas velocity in the riser and as a function of fermentation time. Culture medium rheology was studied through fermentation time and allowed to explain the volumetric mass transfer coefficient behaviour. Rheological behaviour was explained in terms of changes in the morphology of the fungus. Finally, rheological studies let us obtain correlations for gas holdup and volumetric mass transfer coefficient estimation using the superficial gas velocity in the riser and the culture medium apparent viscosity.