Three-dimensional simulation of grain mixing in three different rotating drum designs for solid-state fermentation

A previously published two-dimensional discrete particle simulation model for radial mixing behavior of various slowly rotating drums for solid-state fermentation (SSF) has been extended to a three-dimensional model that also predicts axial mixing. Radial and axial mixing characteristics were predicted for three different drum designs: (1) without baffles; (2) with straight baffles; and (3) with curved baffles. The axial mixing behavior was studied experimentally with video- and image-analysis techniques. In the drum without baffles and with curved baffles the predicted mixing behavior matched the observed behavior adequately. The predicted axial mixing behavior in the drum with straight baffles was predicted less accurately, and it appeared to be strongly dependent on particle rotation, which was in contrast to the other drum designs. In the drum with curved baffles complete mixing in the radial and axial direction was achieved much faster than in the other designs; that is, it was already achieved after three to four rotations. This drum design may therefore be very well suited to SSF. It is concluded that discrete particle simulations provide valuable detailed knowledge about particle transport processes, and this may help to understand and optimize related heat and mass transfer processes in SSF.     

Solid-state fermentation in rotating drum bioreactors: operating variables affect performance through their effects on transport phenomena

Aspergillus oryzae ACM 4996 was grown on an artificial gel-based substrate and on steamed wheat bran during solid-state fermentations in 18.7 L rotating drum bioreactors. For gel fermentations fungal growth decreased as rotational speed increased, presumably due to increased shear. For wheat bran fermentations fungal growth improved under agitated compared to static culture conditions, due to superior heat and mass transfer. We conclude that the effects of operational variables on the performance of SSF bioreactors are mediated by their effects on transport phenomena such as mixing, shear, heat transfer, and mass transfer within the substrate bed. In addition, the substrate characteristics affect the need for and the rates of these transport processes. Different transport phenomena may be rate limiting with different substrates. This work improves understanding of the effects of bioreactor operation on SSF performance.     

Magnetic resonance microscopy analysis of advective transport in a biofilm reactor

In this article we present magnetic resonance microscopy (MRM) characterization of the advective transport in a biofilm capillary reactor. The biofilm generates non-axial flows that are up to 20% of the maximum axial velocity. The presence of secondary velocities of this magnitude alters the mass transport in the bioreactor relative to non-biofilm fouled reactors and questions the applicability of empirical mass transfer coefficient approaches. The data are discussed in the context of simulations and models of biofilm transport and conceptual aspects of transport modeling in complex flows are also discussed. The variation in the residence time distribution due to biofilm growth is calculated from the measured propagator of the motion. Dynamical systems methods applied to model fluid mixing in complex flows are indicated as a template for extending mass transport theory to quantitatively incorporate microscale data on the advection field into macroscale mass transfer models.     

Novel electrodynamic oscillation technique enables enhanced mass transfer and mixing for cultivation in micro-bioreactor

Micro-bioreactors (MBRs) have become an indispensable part for modern bioprocess development enabling automated experiments in parallel while reducing material cost. Novel developments aim to further intensify the advantages as dimensions are being reduced. However, one factor hindering the scale-down of cultivation systems is to provide adequate mixing and mass transfer. Here, vertical oscillation is demonstrated as an effective method for mixing of MBRs with a reaction volume of 20 μL providing adequate mass transfer. Electrodynamic exciters are used to transduce kinetic energy onto the cultivation broth avoiding additional moving parts inside the applied model MBR. The induced vertical vibration leads to oscillation of the liquid surface corresponding to the frequency and displacement. On this basis, the resonance frequency of the fluid was identified as the most decisive factor for mixing performance. Applying this vertical oscillation method outstanding mixing times below 1 s and exceptionally high oxygen transport with volumetric mass transfer coefficients (k_La) above 1,000/hr can be successfully achieved and controlled. To evaluate the applicability of this vertical oscillation mixing for low volume MBR systems, cultivations of Escherichia coli BL21 as proof-of-concept were performed. The dissolved oxygen was successfully online monitored to assure any avoidance of oxygen limitations during the cultivation. The here presented data illustrate the high potential of the vertical oscillation technique as a flexible measure to adapt mixing times and oxygen transfer according to experimental demands. Thus, the mixing technique is a promising tool for various biological and chemical micro-scale applications still enabling adequate mass transfer.     

Measurements of oxygen production rate in flowing Spirulina suspension

Summary The oxygen production rates for a cyanobacterial suspension flowing in straight and coiled tubes were measured to find a way of achieving higher efficiency of light utilization by means of convective mixing. The photosynthetic flow chambers were made of glass tubes and illumination was by fluorescent light. The cyanobacterium used was Spirulina platensis, which has a high growth rate. The oxygen production rate for fluid flow in straight and coiled tubes increase with the increase in Reynolds number. The maximum oxygen production rate was achieved at 30°C for both tube reactors, but the oxygen production rate was higher for the coiled tube unit than the straight tube unit at 30°C. Thus the convective mixing generated in the coiled tube reactor contributed to an increased in light utilization, which played an important part in improving the oxygen production rate. Offprint requests to: K. Tanishita     

Intensification of transfer processes in biotechnology and chemical engineering using static mixers. (Review)

A review of the intensification of moment, mass and heat transfer using an “unconventional” method, namely the application of static mixers, also known as “motionless mixers”, is presented in this paper. After the presentation of some structural types of static mixers, studies with particular emphasis on flow behaviour, pressure drop, mixing, mass and, heat transfer in the presence of static mixing devices, used in biotechnology and chemical engineering, were discussed. The suitability of static mixers to enhance the transfer process parameters was also justified by the low energy requirement, while the fluids might have different viscosities and because of this fact they could remove any mistakes made by the equipment. The article is not directed towards a comprehensive review, but it should serve as a landmark in future undertakings.     

Casson fluid model for pulsatile flow of blood under periodic body acceleration

Pulsatile flow of a Casson fluid under the influence of a periodic body acceleration has been studied in this paper. An implicit finite difference numerical procedure has been used to analyze the flow. Applicability of this method has been checked by comparing the obtained results with the analytical solution for Newtonian flow and explicit scheme solution. The agreement between the implicit and explicit scheme solutions and the analytical solution is good (error less than 1%). Flow variables have been computed at three locations in cardiovascular system (wide (femoral) and narrow (arteriole and coronary) tubes). Effects of yield stress, tube radius and pressure gradient combined, body acceleration amplitude and frequency etc., on flow have been studied. The following observations have been made: (i) Initial transient time It changes with yield stress in narrow tubes are insignificant, whereas in wide tubes It decreases with yield stress; (ii) The axial velocity and fluid acceleration variations with yield stress are uniform (changes only quantitatively, profiles shape remain same) in narrow tubes, whereas in wide tubes these variations are non-uniform (profiles change qualitatively as well as quantitatively); (iii) Yield stress effects on wall shear amplitude are insignificant in narrow tubes (congruent to 0.3% in arteriole and congruent to 6% in femoral); and (iv) For Newtonian fluid, mean flow rate does not change with body acceleration amplitude a0 and frequency fb but it increases (decreases) with a0(fb) for Casson fluid.     

Continuous production of citric acid with recirculation of the fermentation broth after product recovery

An airlift reactor with double net draft tubes was developed. A sparger was located between the two draft tubes. The draft tubes had a significant effect on breaking bubbles into smaller ones. The assessment of the reactor performance was based on gas holdup, mixing time, and volumetric mass transfer coefficient. The proposed reactor had higher gas holdup and volumetric mass transfer coefficient, and lower mixing time in comparison with those of the bubble column. Application of the proposed reactor to fermentation of Saccharomyces cerevisiae demonstrated that the cultivation time was significantly shortened.     

Bolus contaminant dispersion in oscillating flow in curved tubes.

The investigation of longitudinal dispersion of tracer substances in unsteady flows has biomechanical application in the study of heat and mass transport within the bronchial airways during normal, abnormal, and artificial pulmonary ventilation. To model the effects of airway curvature on intrapulmonary gas transport, we have measured local gas dispersion in axially uniform helical tubes of slight pitch during volume-cycled oscillatory flow. Following a small argon bolus injection into the flow field, the time-averaged effective diffusion coefficient (Deff/Dmol) for axial transport of the contaminant was evaluated from the time-dependent local argon concentration measured with a mass spectrometer. The value of (Deff/Dmol) is extracted from the curve of concentration versus time by two techniques yielding identical results. Experiments were conducted in two helical coiled tubes (delta = 0.031, lambda = 0.022 or delta = 0.085, lambda = 0.060) over a range of 2 < alpha < 15, 3 < A < 15, where delta is the ratio of tube radius to radius of curvature, lambda is the ratio of pitch height to radius of curvature, alpha is the Womersley parameter or dimensionless frequency, and A is the stroke amplitude or dimensionless tidal volume. Experimental results show that, when compared to transport in straight tubes, the effective diffusivity markedly increases in the presence of axial curvature. Results also compare favorably to mathematical predictions of bolus dispersion in a curved tube over the ranges of frequency and tidal volume studied.     

Model of the mass transport to the surface of animal cells cultured in a rotating bioreactor operated in micro gravity

A mathematical model is used to investigate the transport of dissolved oxygen from the bulk fluid to the surface of aggregates of animal cells cultured in a rotating bioreactor. These aggregates move through different regions of the bioreactor with a local flow field and concentration distribution that vary with time. The time variation of the Sherwood number and the surface concentration for a range of parameters typical of a cell science experiment executed in the Rotating Wall Perfused Vessel (RWPV) bioreactor in space are investigated. The Reynolds numbers experienced by the aggregate are generally low (Re < 1) and the Peclet numbers range from O(1) to O(100). Comparison of the results from the numerical solution of the mathematical model with those from a quasi-steady model, using a steady-state correlation for mass transport on a sphere, indicate that the quasi-steady assumption is not a good model to compute the instantaneous Sherwood number. This indicates a significant history effect in the Sherwood number response to the variations of acceleration of the aggregates in the bioreactor. A high resistance to the mass transport from the bulk fluid to the surface of the aggregate exists for the bioreactor operated in micro gravity. The difference between the surface concentration and the free stream concentration was as high as 30% for aggregates larger than 3 mm. Diffusion reduces the variations of the free stream concentration resulting in a nearly constant value for the concentration at the surface of the aggregates.     

Pulsatile blood flow effects on temperature distribution and heat transfer in rigid vessels

The effect of blood velocity pulsations on bioheat transfer is studied. A simple model of a straight rigid blood vessel with unsteady periodic flow is considered. A numerical solution that considers the fully coupled Navier-Stokes and energy equations is used for the simulations. The influence of the pulsation rate on the temperature distribution and energy transport is studied for four typical vessel sizes: aorta, large arteries, terminal arterial branches, and arterioles. The results show that: the pulsating axial velocity produces a pulsating temperature distribution; reversal of flow occurs in the aorta and in large vessels, which produces significant time variation in the temperature profile. Change of the pulsation rate yields a change of the energy transport between the vessel wall and fluid for the large vessels. For the thermally important terminal arteries (0.04-1 mm), velocity pulsations have a small influence on temperature distribution and on the energy transport out of the vessels (8 percent for the Womersley number corresponding to a normal heart rate). Given that there is a small difference between the time-averaged unsteady heat flux due to a pulsating blood velocity and an assumed nonpulsating blood velocity, it is reasonable to assume a nonpulsating blood velocity for the purposes of estimating bioheat transfer.     

Helical swimming can provide robust upwards transport for gravitactic single-cell algae; a mechanistic model

In still fluid, many phytoplankton swim in helical paths with an average upwards motion. A new mechanistic model for gravitactic algae subject to an intrinsic torque is developed here, based on Heterosigma akashiwo, which results in upwards helical trajectories in still fluid. The resultant upwards swimming speed is calculated as a function of the gravitactic and intrinsic torques. Helical swimmers have a reduced upwards speed in still fluid compared to cells which swim straight upwards. However a novel result is obtained when the effect of fluid shear is considered. For intermediate values of shear and intrinsic torque, a new stable equilibrium solution for swimming direction is obtained for helical swimmers. This results in positive upwards transport in vertical shear flow, in contrast to the stable equilibrium solution for straight swimmers which results in downwards transport in vertical shear flow. Furthermore, for strong intrinsic torque, when there is no longer a stable orientation equilibrium, we show that the average downwards transport of helical swimmers in vertical shear flow is greatly suppressed compared to straight swimmers. We hypothesise that helical swimming provides robustness for upwards transport in the presence of fluid shearing motions.     

Low reynolds number viscous flow in an alveolated duct

Flow visualization studies and supplementary numerical simulations are carried out on slow flow through a model alveolated duct. The results reveal that the type of flow that develops in the alveoli, or cavities, is controlled by the ratio of the depth to the width of the cavity and by the ratio of cavity volume to duct volume. While weak, the slowly rotating flow in the cavity is thought to be important to the convective transport of heat and mass transfer to, or from, the walls of the cavity. The relevance of these finding to particle transport and deposition deep in the lung is discussed.     

Oscillatory flow and gas transport through a symmetrical bifurcation

Axial gas transport due to the interaction between radial mixing and radially nonuniform axial velocities is responsible for gas transport in thick airways during High-frequency oscillatory ventilation (HFO). Because the airways can be characterized by a bifurcating tube network, the secondary flow in the curved portion of a bifurcating tube contributes to cross-stream mixing. In this study the oscillatory flow and concentration fields through a single symmetrical airway bifurcating tube model were numerically analyzed by solving three-dimensional Navier-Stokes and mass concentration equations with the SIMPLER algorithm. The simulation conditions were for a Womersley number, alpha = 9.1 and Reynolds numbers in the parent tube between 200 and 1000, corresponding to Dn2/alpha 4 in the curved portion between 2 and 80, where Dn is Dean number. For comparison with the results from the bifurcating tube, we calculated the velocity and concentration fields for fully developed oscillatory flow through a curved tube with a curvature rate of 1/10, which is identical to the curved portion of the bifurcating tube. For Dn2/alpha 4 < or = 10 in the curved portion of the bifurcating tube, the flow divider and area changes dominate the axial gas transport, because the effective diffusivity is greater than in either a straight or curved tube, in spite of low secondary velocities. However, for Dn2/alpha 4 > or = 20, the gas transport characteristics in a bifurcation are similar to a curved tube because of the significant effect of secondary flow.     

Evidence for solution flow in the phloem of willow

Sucrose specific mass transfer measurements were made in a translocating willow shoot (Salix viminalis L.) by a steady state labelling technique and the translocate sucrose specific activity, concentration and velocity monitored by analysis of the honeydew from two colonies of the willow aphid Tuberolachnus salignus Gmelin. The values of sucrose SMT obtained were related to the simultaneous measurements of translocate concentration and velocity and to the gradients of sucrose concentration within the stem transport path to determine if transport was a bulk flow or a diffusional analogue. Estimates of potassium ion concentration in the sieve tubes were made, using aphid honeydew, and related to the sucrose SMT measured simultaneously. Correlations were found between translocate concentration, velocity and SMT which suggested that solution flow was occurring rather than a process analogous to diffusion. Evidence was obtained that velocity of flow was a valid concept and that the measured velocity was being lowered by leakage of tracer from the sieve tubes. The analysis of potassium concentration suggested that if solution flow was occurring then potassium must be very exchangeable down the transport path. A good correlation was observed between the SMT of sucrose and the combined gradient of sucrose and potassium concentration, though this gradient was in the opposite direction to transport in some cases.Abbreviations SMT Sucrose specific mass transfer rate - SAR Specific activity ratio - OP Osmotic pressure     

Heat and Mass Transfer in Unsteady Rotating Fluid Flow with Binary Chemical Reaction and Activation Energy

In this study, the Spectral Relaxation Method (SRM) is used to solve the coupled highly nonlinear system of partial differential equations due to an unsteady flow over a stretching surface in an incompressible rotating viscous fluid in presence of binary chemical reaction and Arrhenius activation energy. The velocity, temperature and concentration distributions as well as the skin-friction, heat and mass transfer coefficients have been obtained and discussed for various physical parametric values. The numerical results obtained by (SRM) are then presented graphically and discussed to highlight the physical implications of the simulations.     

Numerical Simulation for the Unsteady MHD Flow and Heat Transfer of Couple Stress Fluid over a Rotating Disk

The present work is devoted to study the numerical simulation for unsteady MHD flow and heat transfer of a couple stress fluid over a rotating disk. A similarity transformation is employed to reduce the time dependent system of nonlinear partial differential equations (PDEs) to ordinary differential equations (ODEs). The Runge-Kutta method and shooting technique are employed for finding the numerical solution of the governing system. The influences of governing parameters viz. unsteadiness parameter, couple stress and various physical parameters on velocity, temperature and pressure profiles are analyzed graphically and discussed in detail.     

The halteres of the blowfly Calliphora

The movement of the halteres during fixed flight was video recorded under stroboscopic illumination phase coupled to the wing beat. The halteres swing in a rounded triangular manner through an angle of almost 80° in vertical planes tilted backwards from the transverse plane by ca. 30° (Figs. 1, 2).The physics of the halteres are described in terms of a general formula for the force acting onto the endknob of the moving haltere during rotations and linear accelerations of the fly (Eq. 1). On the basis of the experimentally determined kinematics of the haltere, the primary forces and the forces dependent on angular velocity and on angular acceleration are calculated (Figs. 3, 4).Three distinct types of angular velocity dependent (Coriolis) forces are generated by rotations about 3 orthogonal axes. Thus, in principle one haltere could detect all rotations in space (Fig. 6).The angular acceleration dependent forces have the same direction and frequency as the Coriolis forces, but they are shifted in phase by 90°. Thus, they could be evaluated in parallel and independently from the Coriolis forces. They are, however, much smaller than the Coriolis forces for oscillation frequencies of the fly up to 20 Hz (Fig. 5). From these considerations it is concluded that Coriolis forces play the major role in detecting body rotations.     

Liquid film bioreactors for cell mass production

In order to make heat and mass transfer processes in bioreactors more intensive, the turbulent liquid film flow which is proposed for realization in multitubular reactors has been developed. Experiments have been carried out in tubes with smooth and rough surfaces at cocurrent gas and liquid film downward flows with a view to determine the values of the mass transfer coefficients in turbulent liquid hold-up in contact tubes. The liquid viscosity and REYNOLDS number are changing in a wide range (from 2000 to 60000). The results show that the maximum values of the mass transfer coefficients and an acceptable hold-up can be obtained in tubes with rough surfaces at high REYNOLDS numbers of the liquid film. The results of culturing yeasts on hydrolyzate in a laboratory-size liquid film fermenter are also presented.     

Heat and water transfer in a rotating drum containing solid substrate particles

In previous work we reported on the simulation of mixing behavior of a slowly rotating drum for solid-state fermentation (SSF) using a discrete particle model. In this investigation the discrete particle model is extended with heat and moisture transfer. Heat transfer is implemented in the model via interparticle contacts and the interparticle heat transfer coefficient is determined experimentally. The model is shown to accurately predict heat transfer and resulting temperature gradients in a mixed wheat grain bed. In addition to heat transfer, the addition and subsequent distribution of water in the substrate bed is also studied. The water is added to the bed via spray nozzles to overcome desiccation of the bed during evaporative cooling. The development of moisture profiles in the bed during spraying and mixing are studied experimentally with a water-soluble fluorescent tracer. Two processes that affect the water distribution are considered in the model: the intraparticle absorption process, and the interparticle transfer of free water. It is found that optimum distribution can be achieved when the free water present at the surface of the grains is quickly distributed in the bed, for example, by fast mixing. Alternatively, a short spraying period, followed by a period of mixing without water addition, can be applied. The discrete particle model developed is used successfully to examine the influence of process operation on the moisture distribution (e.g., fill level and rotation rate). It is concluded that the extended discrete particle model can be used as a powerful predictive tool to derive operating strategies and criteria for design and scale-up for mixed SSF and other processes with granular media.