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.     

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

The effect of gas on solid-liquid hydrodynamics in mixing vessels was studied to determine the agitation speed required to just completely suspend all the particles under gassed conditions, N _jsg and by measurement of the power consumption associated with this agitation speed. The solid particles have a mean diameter between 15–1000 μm. For their mixing are used standard and modified Rushton turbine agitators positioned singly or doubly on the same shaft. The modified turbine with a surface fraction of the perforations equal to 0.353 (TP3) was obtained through increase in the blade height of the Rushton turbine simultaneously with the perforation of the blade surface. The filled surface of the modified blade is equal to the blade surface of the standard Rushton turbine.     

Mass transfer and mixing rates in fermentation vessels

The effects on mass-transfer and overall mixing rates of varying impeller geometry and operating speed have been studied for flat-bladed turbines in laboratory fermentors, in aerated aqueous solutions, and in unaerated and aerated suspensions (1.6% w/v) of paper pulp. In the absence of suspended solid, oxygen absorption rates could be correlated directly with power input. In the pulp suspension, oxygen absorption at a given power input was influenced by impeller geometry and operating speed. The data for the three-phase system can be correlated by a dimensionless equation relating oxygen-transfer rates and mixing times to the geometrical and operating parameters of the impellers.     

Oxygen transfer efficiency in the biosynthesis of antibiotics in bioreactors with a modified RUSHTON turbine agitator

In this work, the oxygen mass transfer efficiency and power consumption in a non-biological system and an antibiotic biosynthesis process, using a modified RUSHTON turbine agitator, were investigated. It was demonstrated that a simple modification of the blades through the increase of the blade height, simultaneously with the discontinuation of the blade surface, could improve the oxygen transfer efficiency by about 30%. Experiments performed in stirred tank bioreactors with an overall volume of 20 m³, equipped with the modified RUSHTON turbine agitator, showed that the power consumption diminished by a factor of 1.18 to 1.6 during the fermentation processes of Streptomyces erithreus, Streptomyces griseus, Streptomyces noursei, and Nocardia mediaterranei, compared to the witness bioreactor. The use of the modified RUSHTON turbine for the antibiotic biosynthesis process may contribute to the decrease of the overall costs and the obtainment of better productivity, allowing an intensive utilization of power inputs for aeration and agitation.     

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.     

Studies on transfer processes in mixing vessels: suspending of solid particles in liquid by modified Rushton turbine agitators

The modified blade turbines are attractive alternatives to the standard Rushton turbine as they do not require any modification in the electrical engine motor and drive assemblies are simple to manufacture and have a reduced power consumption.The modified blades were obtained through increase in the blade height of the Rushton turbine simultaneously with perforation of the blade surface. The field surface of the modified blade is equal to the blade surface of the standard Rushton turbine.In this study the modified blade turbine with the surface fraction of the perforations equal to 0.353 is used.The complete suspension speed and the power dissipation in transition and turbulent regimes using standard and modified Rushton turbine agitators positioned singly or doubly on same shaft, in five solid-liquid systems were investigated.The solid particles used have the mean diameter between 15–1000 m.The modified blade turbine, noted as TP3, was found to be more efficient than the standard turbine in complete and homogeneous suspension.List of Symbols A distance between turbine and the vessel bottom (m) - c dimensionless constant (-) - d agitator diameter (m) - d _p surface-to-volume mean diameter of the particle (m) - D vessel diameter (m) - (H _L )₁ suspension height for one turbine immersed (m) - (H _L )₂ suspension height for two turbines immersed (m) - K consistency index (Pa s ⁿ ) - l _k eddy-size characteristic (m) - N flow behaviour index (-) - N _p number of blades of the mixing system (-) - N agitator speed (s^–1) - N _js agitator speed that just causes complete suspension (s^–1) - Ne P_L/_LN³d⁵ power number in liquid system (-) - (Ne) _g P_g/_spN³d⁵ power number in solid-liquid system (-) - P _L power consumption in liquid system (W) - P _s power consumption in solid-liquid system (W) - r coefficient of correlation (-) - R distance between turbines (m) - Re _spNd²/ _a Reynolds number (-) - S suspension parameter in Zwietering equation (2) (-) - S _C full surface of the blade (m²) - S _G surface of the perforations applied on the blade (m²) - S _G /S _C surface fraction of the perforations (-) - X particle concentration (g/l) - w baffle width (m) - _js specific power input per mass at the complete suspension state (W/kg) - _a apparent viscosity under mixing conditions (Pa s) - _L kinematic viscosity of the liquid (m²/s) - _L density of liquid (Kg/m³) - _s density of solid (Kg/m³) - _sp density of suspension (Kg/m³)     

Power consumption of three impeller combinations in mixing Xanthan fermentation broths

Xanthan gum fermentation represents a good model for the study of the mixing of rheologically complex culture broths. Most of the previous work on power consumption dealt with ‘standard’, single impellers and used model fluids to simulate xanthan broths. This work describes the characterization of three dual-impeller combinations (D/T = 0·53) for the mixing of dehydrated—reconstituted fermentation broths of Xanthomonas campestris that had matched rheology to the actual broths. The bottom impeller was a Rushton turbine (RT) and the top impeller was another RT, a 45° pitched blade turbine (PT) or an A-310 Lightnin mixer (A310). The experiments were carried out in a tank of 0·0094 m³ working volume equipped with an air bearing dynamometer. The power was measured in a wide range of xanthan concentrations (5–40 kg m⁻³) in aerated (0·25, 0·5 and 1·0 vvm) and unaerated conditions. Unaerated power number (Po) vs. Reynolds number (Re) curves showed similar trends for the three combinations. Exponents close to −1 were obtained in the laminar region. A minimum in Po (Po_min) occurred at Re = 30–40, then increasing to a plateau value which was evident at Re> 200. In the transition region Po_min values were 4·3 (RT and RT), 3·6 (RT and PT) and 2·4 (RT and A310). The aerated power data for (RT and PT) and (RT and A-310) showed higher torque instabilities than the dual RT combinations at higher xanthan concentrations. The higher the xanthan concentrations, the higher the drop in power and the less important the effect of the aeration rate. Among the combinations tested, when using Rushton turbines, the well-mixed ‘cavern’ reached the tank wall (i.e., fluid motion was observed) at the lowest volumetric power input. High     

Scale-up on basis of structured mixing models: A new concept

A new scale-up concept based upon mixing models for bioreactors equipped with Rushton turbines using the tanks-in-series concept is presented. The physical mixing model includes four adjustable parameters, i.e., radial and axial circulation time, number of ideally mixed elements in one cascade, and the volume of the ideally mixed turbine region. The values of the model parameters were adjusted with the application of a modified Monte-Carlo optimization method, which fitted the simulated response function to the experimental curve. The number of cascade elements turned out to be constant (N = 4). The model parameter radial circulation time is in good agreement with the one obtained by the pumping capacity. In case of remaining parameters a first or second order formal equation was developed, including four operational parameters (stirring and aeration intensity, scale, viscosity). This concept can be extended to several other types of bioreactors as well, and it seems to be a suitable tool to compare the bioprocess performance of different types of bioreactors. (c) 1994 John Wiley & Sons, Inc.     

Mixing design for enzymatic hydrolysis of sugarcane bagasse: methodology for selection of impeller configuration

One of the major process bottlenecks for viable industrial production of second generation ethanol is related with technical–economic difficulties in the hydrolysis step. The development of a methodology to choose the best configuration of impellers towards improving mass transfer and hydrolysis yield together with a low power consumption is important to make the process cost-effective. In this work, four dual impeller configurations (DICs) were evaluated during hydrolysis of sugarcane bagasse (SCB) experiments in a stirred tank reactor (3 L). The systems tested were dual Rushton turbine impellers (DIC1), Rushton and elephant ear (down-pumping) turbines (DIC2), Rushton and elephant ear (up-pumping) turbines (DIC3), and down-pumping and up-pumping elephant ear turbines (DIC4). The experiments were conducted during 96 h, using 10 % (m/v) SCB, pH 4.8, 50 °C, 10 FPU/g_biomass, 470 rpm. The mixing time was successfully used as the characteristic parameter to select the best impeller configuration. Rheological parameters were determined using a rotational rheometer, and the power consumptions of the four DICs were on-line measured with a dynamometer. The values obtained for the energetic efficiency (the ratio between the cellulose to glucose conversion and the total energy) showed that the proposed methodology was successful in choosing a suitable configuration of impellers, wherein the DIC4 obtained approximately three times higher energetic efficiency than DIC1. Furthermore a scale-up protocol (factor scale-up 1000) for the enzymatic hydrolysis reactor was proposed.     

Performance of industrial scale bioreactors with modified RUSHTON turbine agitators

The data presented here with respect to the behaviour of industrial scale stirred tank bioreactors equipped with modified RUSHTON turbine agitators in the biosynthesis processes of antibiotics are valid for that case that the power consumption is the same as it is in standard RUSHTON turbine agitators. Each modified RUSHTON turbine agitator was obtained through the variation of the blade surface by adding perforations so that the ratio between the perforation surface area and the full surface area (or the surface fraction of the perforations) is 0.36. In the fermentations of Streptomyces aureofaciens, Streptomyces rimosus and Penicillium chrysogenum producing tetracycline, oxytetracyline and penicillin, respectively, in bioreactors equipped with modified RUSHTON turbine agitators, the relative antibiotic production is increased by more than 30% compared to standard bioreactors.     

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.     

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.     

A special reactor design for investigations of mixing time effects in a scaled‐down industrial L‐lysine fed‐batch fermentation process

A specially designed model reactor based on a 42‐L laboratory fermentor was equipped with six stirrers (Rushton turbines) and five cylindrical disks. In this model reactor, the mixing time, Θ₉₀, turned out to be 13 times longer compared with the 42‐L standard laboratory fermentor fitted with two Rushton turbines and four wall‐fixed longitudinal baffles. To prove the suitability of the model reactor for scaledown studies of mixing‐time‐dependent processes, parallel exponential fed‐batch cultivations were carried out with the leucine‐auxotrophic strain, Corynebacterium glutamicum DSM 5715, serving as a microbial test system. L‐ Leucine, the process‐limiting substrate, was fed onto the liquid surface of both reactors. Cultivations were conducted using the same inoculum material and equal oxygen supply. The model reactor showed reduced sugar consumption (−14%), reduced ammonium consumption (−19%), and reduced biomass formation (−7%), which resulted in a decrease in L ‐lysine formation (−12%). These findings were reflected in less specific enzyme activity, which was determined for citrate synthase (CS), phosphoenolpyruvate carboxylase (PEP‐C), and aspartate kinase (AK). The reduced specific activity of CS correlated with lower CO₂ evolution (−36%) during cultivation. The model reactor represents a valuable tool to simulate the conditions of poor mixing and inhomogeneous substrate distribution in bioreactors of industrial scale. © 1999 John Wiley & Sons, Inc. Biotechnol Bioeng 64: 599–606, 1999.     

Paint it black: Efficacy of increased wind turbine rotor blade visibility to reduce avian fatalities

As wind energy deployment increases and larger wind‐power plants are considered, bird fatalities through collision with moving turbine rotor blades are expected to increase. However, few (cost‐) effective deterrent or mitigation measures have so far been developed to reduce the risk of collision. Provision of “passive” visual cues may enhance the visibility of the rotor blades enabling birds to take evasive action in due time. Laboratory experiments have indicated that painting one of three rotor blades black minimizes motion smear (Hodos 2003, Minimization of motion smear: Reducing avian collisions with wind turbines). We tested the hypothesis that painting would increase the visibility of the blades, and that this would reduce fatality rates in situ, at the Smøla wind‐power plant in Norway, using a Before–After–Control–Impact approach employing fatality searches. The annual fatality rate was significantly reduced at the turbines with a painted blade by over 70%, relative to the neighboring control (i.e., unpainted) turbines. The treatment had the largest effect on reduction of raptor fatalities; no white‐tailed eagle carcasses were recorded after painting. Applying contrast painting to the rotor blades significantly reduced the collision risk for a range of birds. Painting the rotor blades at operational turbines was, however, resource demanding given that they had to be painted while in‐place. However, if implemented before construction, this cost will be minimized. It is recommended to repeat this experiment at other sites to ensure that the outcomes are generic at various settings.     

Studies with a multiple-rod mixing impeller

The performance of a multiple-rod mixing impeller was compared to that of conventional turbine impellers in viscous novobiocin beers. The advantages of the multiple-rod impeller were found to be: (1) the power requirement was independent of changes in apparent viscosity of the fermentation beer; and (2) it gave the same novobiocin yield and oxygen-availability rate at about one-half of the power required by turbines.     

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.     

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.     

Power consumption and maximum energy dissipation in a milliliter‐scale bioreactor

Mean power consumption and maximum local energy dissipation were measured as function of operating conditions of a milliliter‐scale stirred tank bioreactor (V = 12 mL) with a gas‐inducing impeller. A standard laboratory‐scale stirred tank bioreactor (V = 1,200 mL) with Rushton turbines was used as reference. The measured power characteristics (Newton number as function of Reynolds number) were the same on both scales. The changeover between laminar and turbulent flow regime was observed at a Reynolds number of 3,000 with the gas‐inducing stirrer on a milliliter‐scale. The Newton number (power number) in the turbulent flow regime was 3.3 on a milliliter‐scale, which is close to values reported for six‐blade Rushton turbines of standard bioreactors. Maximum local energy dissipation (ε_max) was measured using a clay/polymer flocculation system. The maximum local energy dissipation in the milliliter‐scale stirred tank bioreactor was reduced compared with the laboratory‐scale stirred tank at the same mean power input per unit mass (ε_ø), yielding ε_max/ε_ø ≈ 10 compared with ε_max/ε_ø ≈ 16. Hence, the milliliter‐scale stirred tank reactor distributes power more uniformly in the reaction medium. These results are in good agreement with literature data, where a decreasing ε_max/ε_ø with increasing ratio of impeller diameter to reactor diameter is found (d/D = 0.7 compared with d/D = 0.4). Based on these data, impeller speeds can now be easily adjusted to achieve the same maximum local energy dissipation at different scales. This enables a more reliable and robust scale‐up of bioprocesses from milliliter‐scale to liter‐scale reactors. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2010     

Life Cycle Assessment for Emerging Technologies: Case Studies for Photovoltaic and Wind Power (11 pp)

Goal, Scope and Background This paper describes the modelling of two emerging electricity systems based on renewable energy: photovoltaic (PV) and wind power. The paper shows the approach used in the ecoinvent database for multi-output processes.Methods Twelve different, grid-connected photovoltaic systems were studied for the situation in Switzerland. They are manufactured as panels or laminates, from mono- or polycrystalline silicon, installed on facades, slanted or flat roofs, and have a 3kWp capacity. The process data include quartz reduction, silicon purification, wafer, panel and laminate production, supporting structure and dismantling. The assumed operational lifetime is 30 years. Country-specific electricity mixes have been considered in the LCI in order to reflect the present situation for individual production stages. The assessment of wind power includes four different wind turbines with power rates between 30 kW and 800 kW operating in Switzerland and two wind turbines assumed representative for European conditions – 800 kW onshore and 2 MW offshore. The inventory takes into account the construction of the plants including the connection to the electric grid and the actual wind conditions at each site in Switzerland. Average European capacity factors have been assumed for the European plants. Eventually necessary backup electricity systems are not included in the analysis.Results and Discussion The life cycle inventory analysis for photovoltaic power shows that each production stage may be important for specific elementary flows. A life cycle impact assessment (LCIA) shows that there are important environmental impacts not directly related to the energy use (e.g. process emissions of NOx from wafer etching). The assumption for the used supply energy mixes is important for the overall LCIA results of different production stages. The allocation of the inventory for silicon purification to different products is discussed here to illustrate how allocation has been implemented in ecoinvent. Material consumption for the main parts of the wind turbines gives the dominant contributions to the cumulative results for electricity production. The complex installation of offshore turbines, with high requirements of concrete for the foundation and the assumption of a shorter lifetime compared to onshore foundations, compensate the advantage of increased offshore wind speeds.Conclusion The life cycle inventories for photovoltaic power plants are representative for newly constructed plants and for the average photovoltaic mix in Switzerland in the year 2000. A scenario for a future technology helps to assess the relative influence of technology improvements for some processes in the near future (2005-2010). The differences for environmental burdens of wind power basically depend upon the capacity factor of the plants, the lifetime of the infrastructure, and the rated power. The higher these factors, the more reduced the environmental burdens are. Thus, both systems are quite dependent on meteorological conditions and the materials used for the infrastructure.Recommendation and Perspective Many production processes for photovoltaic power are still under development. Future updates of the LCI should verify the energy uses and emissions with available data from industrial processes in operation. For the modelling of a specific power plant or power plant mixes outside of Switzerland, one has to consider the annual yield (kWh/kWp) and if possible also the size of the plant. Considering the steady growth of the size of wind turbines in Europe, the development of new designs, and the exploitation of offshore location with deeper waters than analysed in this study, the inventory for wind power plants may need to be updated in the future.     

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.