Mass transfer in an airlift reactor with a net draft tube.

Gas-liquid mass transfer in an airlift reactor with net draft tube is investigated. The effects of both the ratio of draft tube to reactor diameter and the reactor pressure on oxygen transfer are considered. The value of the volumetric mass transfer coefficient, kLa, increases with a decreasing diameter ratio at higher air flow rates. The correlation of volumetric mass transfer coefficient with respect to the true superficial air velocity under different reactor pressures is determined. The kLa value decreases with increasing reactor pressure.     

Enhancement of glucose oxidase production in batch cultivation of recombinant Saccharomyces cerevisiae: optimization of oxygen transfer condition

AIMS: To obtain an optimal combination of agitation speed and aeration rate for maximization of specific glucose oxidase (GOD) production in recombinant Saccharomyces cerevisiae, and to establish a correlation between kLa vis-à-vis oxygen transfer condition and specific glucose oxidase production. METHODS AND RESULTS: The oxygen transfer condition was manifested indirectly by manipulating the impeller speed and aeration rate in accordance with a Central Composite Rotatory Design (CCRD). The dissolved oxygen concentration and the volumetric oxygen transfer coefficient (kLa) were determined at corresponding combinations of impeller speed and aeration rate. The maximal specific extracellular glucose oxidase production (3.17 U mg-1 dry cell mass) was achieved when the initial dissolved oxygen concentration was 6.83 mg l-1 at the impeller speed of 420 rev min-1 and at the rate of aeration of 0.25 vvm. It was found out that while impeller speed had a direct effect on the production of enzyme, a correlation between kLa and specific GOD production could not be established. CONCLUSION: At the agitation speed of 420 rev min-1 and at 0.25 vvm aeration rate, the degree of turbulence and the dissolved oxygen concentration were thought to be optimal both for cellular growth and production of enzyme. SIGNIFICANCE AND IMPACT OF THE STUDY: The combined effect of agitation and aeration on recombinant glucose oxidase production in batch cultivation has not yet been reported in the literature. Therefore, this study gives an insight into the effect of these two important physical parameters on recombinant protein production. It also suggests that since there is no correlation between kLa and specific production of GOD, kLa should not be used as one of the scale-up parameters.     

Gas-liquid dispersion with dual Rushton turbine impellers

Aerated and unaerated power consumption and flow patterns in a 0.56 m diameter agitated vessel containing water with dual Rushton turbines have been studied. Under unaerated conditions with a liquid height-to-diameter ratio of 2, an impeller spacing of 2 to 3 times the impeller is required for each to draw an amount of power equal to a single impeller. For aerated conditions, if a similar spacing is used, equations for the flooding-loading transition and for power consumption for a single Rushton impeller can be extended relatively easily to dual systems. All results for this spacing are explained by reference to bulk flow patterns and gassed-filled cavity structures and the proportion of sparged gas flowing through the upper impeller is also estimated. Such a spacing is generally recommended since it maximizes the power draw and hence the potential for oxygen mass transfer. Data are presented for other spacings but the results do not fit in easily with single agitator studies because strong impeller-impeller flow pattern interactions occur.     

三相逆流湍动床气液传质性能的研究

由空气-水(清水/废水)-中空玻璃珠构成三相体系,在表观气速0·53~10mm·s-1、固含率为0~0·3、表观液速0~0·2mm·s-1的条件下,采用溶氧仪研究了三相逆流湍动床的气液传质性能,考察了操作参数和液体性质对液相容积传质系数kLa的影响。结果表明,在所试条件下,kLa为0·0456~1·414min-1。kLa随着表观气速和表观液速的增加而增加,随着固含率的增加先增加后减小,0·05~0·08为反应器传质的最优固含率条件。液体性质对kLa有重大影响,高浓度模拟废水和工业废水中的kLa比清水中的kLa分别减小39·0%和50·9%。研究结果可为后续逆流湍动床废水生物处理过程分析与模拟提供传质基础数据。     

Scale-up of biotransformation process in stirred tank reactor using dual impeller bioreactor

The gas-liquid mass transfer coefficient K(L)a in the fermenter is a strong function of mode of energy dissipation and physico-chemical properties of the liquid media. A combination of disc turbine (DT) and pitched blade turbine down flow (PTD) impellers has been tested in laboratory bioreactor for gas hold-up and gas-liquid mass transfer performance for the growth and biotransformation medium for an yeast isolate VS1 capable of biotransforming benzaldehyde to L-phenyl acetyl carbinol (L-PAC) and compared with those in water.Correlations have been developed for the prediction of the fractional gas hold-up and gas-liquid mass transfer coefficient for the above media. The mass transfer coefficient and respiration rate have been determined in the shake flask for the growth as well as for biotransformation medium. These results, then have been used to optimize the operating parameters (impeller speed and aeration) for growth and biotransformation in a laboratory bioreactor. The comparison of cell mass production and L-PAC production in the bioreactor has been done with that obtained in shake flask studies.     

Studies on fluid dynamics of the flow field and gas transfer in orbitally shaken tubes

Orbitally shaken cylindrical bioreactors [OrbShake bioreactors (OSRs)] without an impeller or sparger are increasingly being used for the suspension cultivation of mammalian cells. Among small volume OSRs, 50‐mL tubes with a ventilated cap (OSR50), originally derived from standard laboratory centrifuge tubes with a conical bottom, have found many applications including high‐throughput screening for the optimization of cell cultivation conditions. To better understand the fluid dynamics and gas transfer rates at the liquid surface in OSR50, we established a three‐dimensional simulation model of the unsteady liquid forms (waves) in this vessel. The studies verified that the operating conditions have a large effect on the interfacial surface. The volumetric mass transfer coefficient (k_La) was determined experimentally and from simulations under various working conditions. We also determined the liquid‐phase mass transfer coefficient (k_L) and the specific interfacial area (a) under different conditions to demonstrate that the value of a affected the gas transfer rate more than did the value of k_L. High oxygen transfer rates, sufficient for supporting the high‐density culture of mammalian cells, were found. Finally, the average axial velocity of the liquid was identified to be an important parameter for maintaining cells in suspension. Overall these studies provide valuable insights into the preferable operating conditions for the OSR50, such as those needed for cell cultures requiring high oxygen levels. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 33:192–200, 2017     

Mass transfer and hydrodynamic characteristics of unbaffled stirred bio-reactors: Influence of impeller design

Unbaffled stirred tanks are increasingly recognized as a viable alternative to common baffled tanks for a range of processes where the presence of baffles is undesirable for some reason. For instance, in the case of shear sensitive cell cultivation (e.g. human cells), unbaffled tanks have been recently found to be able to provide sufficient mass transfer through the free surface vortex. As a consequence the need for bubble formation and subsequent bursting, along with relevant cells damage, is conveniently avoided. In this work the influence of impeller geometry on mass transfer performance and power demand of an unbaffled stirred vessel operating both in sub-critical conditions (the free surface vortex has not yet reached the impeller) and in super-critical conditions (the free surface vortex has reached the impeller and a gas phase is ingested and dispersed inside the reactor) is presented.Experimental results show that the mass transfer performance of unbaffled systems is mainly affected by specific power consumption. Among the stirrer geometries investigated a simple PBT was found to provide the most interesting oxygen transfer performance in the sub-critical regime, and can therefore be regarded as a particularly suitable stirrer for shear sensitive cultures. As regards the super-critical regime, unbaffled tanks are found to provide a performance comparable with that of the standard (baffled) bioreactors, hence resulting in a viable alternative also for fermentations involving robust cells.     

Impact of nozzle operation on mass transfer in jet aerated loop reactors. Characterization and comparison to an aerated stirred tank reactor

The impact of mass transfer on productivity can become a crucial aspect in the fermentative production of bulk chemicals. For highly aerobic bioprocesses the oxygen transfer rate (OTR) and productivity are coupled. The achievable space time yields can often be correlated to the mass transfer performance of the respective bioreactor. The oxygen mass transfer capability of a jet aerated loop reactor is discussed in terms of the volumetric oxygen mass transfer coefficient k_La [h^?1] and the energetic oxygen transfer efficiency E [kgO₂ kW^?1 h^?1]. The jet aerated loop reactor (JLR) is compared to the frequently deployed aerated stirred tank reactor. In jet aerated reactors high local power densities in the mixing zone allow higher mass transfer rates, compared to aerated stirred tank reactors. When both reactors are operated at identical volumetric power input and aeration rates, local k_La values up to 1.5 times higher are possible with the JLR. High dispersion efficiencies in the JLR can be maintained even if the nozzle is supplied with pressurized gas. For increased oxygen demands (above 120 mmol L^?1 h^?1) improved energetic oxygen transfer efficiencies of up to 100 % were found for a JLR compared to an aerated stirred tank reactor operating with Rushton turbines.     

Improvement of mixing time,mass transfer,and power consumption in an external loop airlift photobioreactor for microalgae cultures

Longer mixing times and higher power consumption are common problems in the design of photobioreactors. In this study, a vertical triangular external airlift loop photobioreactor was designed, constructed and operated for microalgae production studies. Gas feeding was performed by two spargers: one at the bottom of the hypotenuse (downcomer) and another at the bottom of the vertical side (riser). This configuration provided more effective countercurrent liquid–gas flow in the hypotenuse. The mass transfer coefficient, gas hold-up, mixing time, circulation time, dimensionless mixing time, bubble size, and volumetric power consumption were measured and optimized using response surface methodology. Investigations were carried out on the performance of the riser (the vertical side), downcomer (the hypotenuse), and separator. The countercurrent flow in the hypotenuse provided sufficient contact between gas and liquid phases, and increased mixing and mass transfer rates, in contrast to the results of previous studies. The promising results of this geometry were shorter mixing time and a significant decrease in volumetric power consumption in comparison with other configurations for photobioreactors.     

Prediction of gas-liquid mass transfer coefficient in sparged stirred tank bioreactors

Oxygen mass transfer in sparged stirred tank bioreactors has been studied. The rate of oxygen mass transfer into a culture in a bioreactor is affected by operational conditions and geometrical parameters as well as the physicochemical properties of the medium (nutrients, substances excreted by the micro-organism, and surface active agents that are often added to the medium) and the presence of the micro-organism. Thus, oxygen mass transfer coefficient values in fermentation broths often differ substantially from values estimated for simple aqueous solutions. The influence of liquid phase physicochemical properties on kLa must be divided into the influence on k(L) and a, because they are affected in different ways. The presence of micro-organisms (cells, bacteria, or yeasts) can affect the mass transfer rate, and thus kLa values, due to the consumption of oxygen for both cell growth and metabolite production. In this work, theoretical equations for kLa prediction, developed for sparged and stirred tanks, taking into account the possible oxygen mass transfer enhancement due to the consumption by biochemical reactions, are proposed. The estimation of kLa is carried out taking into account a strong increase of viscosity broth, changes in surface tension and different oxygen uptake rates (OURs), and the biological enhancement factor, E, is also estimated. These different operational conditions and changes in several variables are performed using different systems and cultures (xanthan aqueous solutions, xanthan production cultures by Xanthomonas campestris, sophorolipids production by Candida bombicola, etc.). Experimental and theoretical results are presented and compared, with very good results.     

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.     

Gas-liquid mass transfer in bioreactor with three-phase inverse fluidized bed

In the present study the oxygen mass transfer from the gas to the aqueous phase in a Three-Phase Inverse Fluidized Bed (TPIFB) has been studied. A pilot scale TPIFB has been designed and constructed. For determination of the volumetric oxygen mass transfer coefficient the elegant dynamic method, described by Dang et al. (1977) was used. The influence of hydrodynamic parameters, e.g., superficial velocities of the gas and liquid phases on the mass transfer rate was studied. In the range of variables covered, it was found that the superficial liquid velocity had a weak effect on the mass transfer whereas the gas flowrate affects the mass transfer positively. The results for the volumetric oxygen transfer coefficient in the TPIFB were compared to reported values of that coefficient, measured in a classic three-phase fluidised bed under similar hydrodynamic conditions and solid phase properties. The comparison demonstrated a two-fold increase of the oxygen transfer rate in the inverse bed over that in the classic one.     

Promotion of oxygen transfer in three-phase fluidized-bed bioreactors by floating bubble breakers

The objective of the present study was to investigate a method to enhance the volumetric rate of oxygen transfer in three-phase fluidized-bed bioreactors. The rates of oxygen transfer from air bubbles to viscous liquid media were promoted by floating bubble breakers in three-phase fluidized beds operated in the bubble coalescing regime. The liquid-phase volumetric oxygen transfer coefficient has been recovered by fitting the axial dispersion model to the resultant data, and its dependence on the experimental variables, such as the gas and liquid flow rates, particle size, concentration of bubble breakers, and liquid viscosity, has been examined. The results indicate that the liquid-phase volumetric oxygen transfer coefficient can be enhanced up to 20-25%. The coefficient exhibits a maximum with respect to the volume ratio of the floating bubble breakers to the fluidized solid particles; it increases with increases in the gas and liquid flow rates and size of fluidized particles, while it decreases with an increase in the liquid viscosity. An expression has been developed to correlate the liquid-phase volumetric oxygen transfer coefficient with the experimental variables.     

Influence of impeller type on mass transfer in fermentation vessels

Radial flow Rushton impellers were compared qualitatively with axial flow hydrofoil impellers (Maxflo T and A315) at the pilot scale. Six types of impellers were compared for qualitative differences in mass transfer. Measurements were conducted using three model systems: water, glycerol and Melojel (soluble starch). Power measurements were obtained using watt transducers, which although limited in accuracy and prone to interferences, were able to provide useful qualitative monitoring results. While there was little effect of impeller type on mass transfer as measured by the rapid pressure increase technique, significant qualitative differences were observed using the rapid temperature increase technique specifically for the Melojel and glycerol model systems. The Miller correlation, relating gassed-to-ungassed power, was used effectively to qualitatively evaluate the power drop upon gassing for both the model systems and a Streptomyces fermentation for the various impeller types. A high oxygen demand Streptomcyes fermentation then was conducted in fermenters possessing each type of impeller. Performance was not adequate with the A315 impellers pumping upwards and the small diameter Maxflo T impellers. Peak titers and profiles of the estimated apparent broth viscosity varied depending upon the impeller type. Mass transfer rates generally declined with higher viscosities when other fermentation operating conditions where held constant. Overall, values for OUR, k _L a, P _g /V _L and other calculated mass transfer and power input quantities for the A315 pumping upwards and undersized Maxflo T (D _T /D _I ?=?2.3) impellers were at the lower end of the range obtained for the larger Maxflo T (D _T /D _I ?=?1.8–2.0) and A315 impellers pumping downwards. Rushton impellers generally behaved qualitatively similar to hydrofoil impellers based on these calculated quantities.     

Rates of glucose oxidation with a column reactor utilizing a magnetic field

Rates of glucose oxidation were measured with the use of a fluidized-bed column placed in a magnetic field and magnetite-containing beads of immobilized glucose oxidase and catalase. Its performance was predicted from the volumetric coefficient for liquid-phase mass transfer and the kinetic constants for glucose oxidation. Effusion of beads was negligible under the operating conditions employed.     

Use of silicone membranes to enhance gas transfer during microbial fuel cell operation on carbon monoxide

Electricity generation in a microbial fuel cell (MFC) using carbon monoxide (CO) or synthesis gas (syngas) as a carbon source has been demonstrated recently. A major challenge associated with CO or syngas utilization is the mass transfer limitation of these sparingly soluble gases in the aqueous phase. This study evaluated the applicability of a dense polymer silicone membrane and thin wall silicone tubing for CO mass transfer in MFCs. Replacing the sparger used in our previous study with the membrane systems for CO delivery resulted in improved MFC performance and CO transformation efficiency. A power output and CO transformation efficiency of up to 18 mW (normalized to anode compartment volume) and 98%, respectively, was obtained. The use of membrane systems offers the advantage of improved mass transfer and reduced reactor volume, thus increasing the volumetric power output of MFCs operating on a gaseous substrate such as CO.     

The influence of impeller type in pilot scale xanthan fermentations

The rheological complexity of Xanthan fermentations presents an interesting problem from a mixing viewpoint, because the phenomena of poor bulk blending and low oxygen mass transfer rates inherent in highly viscous fermentations (and their consequences) can be systematically investigated, even at the pilot plant scale. This study in a 150 L fermentor compares the physical and biological performance of four pairs of impellers: a standard Rushton turbine, a large diameter Rushton turbine, a Prochem Maxflo T, and a Scaba 6SRGT. Accurate in-fermentor power measurements, essential for the comparison of impellers in relation to operating costs are also reported. It is demonstrated that the agitator performance in Xanthan fermentations is very specific and the choice of which impeller to use in bioreactors to obtain enhanced performance is dependant on the applied criterion. None of the criterion favored the use of the standard Rushton turbine, therefore suggesting that there are strong grounds for retrofitting these impellers with either large diameter impellers of similar design or with novel agitators. In addition, fluid dynamic modeling of cavern formation has clearly highlighted the importance of a well mixed and oxygenated region for providing the capacity for high microbial oxygen uptake rates which govern Xanthan productivity and quality. Copyright 1998 John Wiley & Sons, Inc.     

Expressions of mass transfer coefficients of bubbles and free surface of culture tanks using the <Emphasis Type="Italic">k</Emphasis>–ɛ turbulence model

For mammalian cell culture, getting a continuous supply of oxygen and extracting carbon dioxide are primary challenges even in the most modern biopharmaceutical manufacturing plants, due to the low oxygen solubility and excessive carbon dioxide accumulation. In addition, various independent flow and mass transfer characteristics in the culture tanks vessel make scale-up extremely difficult. One method for overcoming these and providing rational optimization is solving the fluid and mass transport equations by numerical simulation. To develop a simulation program, it is decisively important to know mass transfer coefficients of gaseous species in the culture tank. In this study, oxygen mass transfer coefficients are measured using a beaker with a sparger and impellers. In order to investigate the formulation of the mass transfer coefficients, the turbulent flow statistics is calculated by a CFD code for all cases, and the expressions of the mass transfer coefficients are established as functions of the statistics. Until now, the expression by Kawase is known in this field. This expression becomes a function only of energy dissipation rate epsilon. It does not coincide with the conventional experimental fact that mass transfer coefficient is proportional power 0.5 of impeller rotation speed. The new mass transfer coefficient is dependent on both of energy dissipation rate epsilon and turbulent flow energy k. It satisfies the relation of power of 0.5 of impeller rotation speed.     

Evaluation of a novel Wave Bioreactor® cellbag for aerobic yeast cultivation

The Wave Bioreactor is widely used in cell culture due to the benefits of disposable technology and ease of use. A novel cellbag was developed featuring a frit sparger to increase the system's oxygen transfer. The purpose of this work was to evaluate the sparged cellbag for yeast cultivation. Oxygen mass transfer studies were conducted in simulated culture medium and the sparged system's maximum oxygen mass transfer coefficient (kLa) was 38 h(-1). These measurements revealed that the sparger was ineffective in increasing the oxygen transfer capacity. Cultures of Saccharomyces cerevisiae were successfully grown in oxygen-blended sparged and oxygen-blended standard cellbags. Under steady state conditions for both cellbag designs, kLa values as high as 60 h(-1) were obtained with no difference in growth characteristics. This is the first report of a successful cultivation of a microbe in a Wave Bioreactor comparing conventional seed expansion in shake flasks and stirred tank bioreactors.     

Hydrodynamics and mass transfer coefficient in activated sludge aerated stirred column reactor: experimental analysis and modeling

The aerated stirred reactor (ASR) has been widely used in biochemical and wastewater treatment processes. The information describing how the activated sludge properties and operation conditions affect the hydrodynamics and mass transfer coefficient is missing in the literature. The aim of this study was to investigate the influence of flow regime, superficial gas velocity (U(G)), power consumption unit (P/V(L)), sludge loading, and apparent viscosity (mu(ap)) of activated sludge fluid on the mixing time (t(m)), gas hold-up (epsilon), and volumetric mass transfer coefficient (k(L)a) in an activated sludge aerated stirred column reactor (ASCR). The activated sludge fluid performed a non-Newtonian rheological behavior. The sludge loading significantly affected the fluid hydrodynamics and mass transfer. With an increase in the U(G) and P/V(L), the epsilon and k(L)a increased, and the t(m), decreased. The epsilon, k(L)a, and t(m), were influenced dramatically as the flow regime changed from homogeneous to heterogeneous patterns. The proposed mathematical models predicted the experimental results well under experimental conditions, indicating that the U(G), P/V(L), and mu(ap) had significant impact on the t(m), epsilon, and k(L)a. These models were able to give the t(m), epsilon, and k(L)a values with an error around +/-8%, and always less than +/-10%.