A novel split-cylinder airlift reactor for fed-batch cultures

Conventional airlift reactors are not adequate to carry out variable volume processes since it is not possible to achieve a proper liquid circulation in these reactors until the liquid height is higher than that of the downcomer. To carry out processes of variable volume, the use of a split-cylinder airlift reactor is proposed, in the interior of which two multi-perforated vertical baffles are installed in order to provide several points of communication between the reactor riser and downcomer. This improves the liquid circulation and mixing at any liquid volume. In fed-batch cultures, it is important to know how liquid height affects the hydrodynamic characteristics and the volumetric oxygen transfer coefficient since this impacts on the kinetic behavior of any fermentation. Thus, in the present work, the effect of the liquid height on the mixing time, the overall gas hold-up, and the volumetric oxygen transfer coefficient of the proposed airlift reactor were determined. The mixing time was increased and the volumetric oxygen transfer coefficient decreased due to the increase of the liquid height in the reactor in all the superficial gas velocities tested, which corresponded to a pseudohomogeneous flow regime. The experimental values of the mixing time and the mass-transfer coefficient were properly described through correlations in which the U_GR/H_L ratio was used as the independent variable. Thus, this variable might be used to describe the hydrodynamic behavior and the oxygen transfer coefficient of airlift reactors when such reactors are used in processes where the liquid volume changes with time. However, these correlations are useful for the particular device and for the particular operating conditions at which they were obtained. These empirical correlations are useful to understand some factors that influence the mixing time and volumetric oxygen transfer coefficient, but such correlations do not have a sufficient predictive potential for a satisfactory reactor design. The overall gas hold-up values were not significantly affected when the liquid height was lower than the downcomer height. However, the values decreased abruptly when the reactor was operated with liquid heights over the downcomer height, especially at high superficial gas velocities.     

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.     

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.     

Improvement of mass transfer characteristics and productivities of inclined tubular photobioreactors by installation of internal static mixers

The feasibility of improving mass transfer characteristics of inclined tubular photobioreactors by installation of static mixers was investigated. The mass transfer characteristics of the tubular photobioreactor varied depending on the type (shape) and the number of static mixers. The volumetric oxygen transfer coefficient ( k(L)a) and gas hold up of the photobioreactor with internal static mixers were significantly higher than those of the photobioreactor without static mixers. The k(L)a and gas hold up increased with the number of static mixers but the mixing time became longer due to restricted liquid flow through the static mixers. By installing the static mixers, the liquid flow changed from plug flow to turbulent mixing so that cells were moved between the surface and bottom of the photobioreactor. In outdoor culture of Chlorella sorokiniana, the photobioreactor with static mixers gave higher biomass productivities irrespective of the standing biomass concentration and solar radiation. The effectiveness of the static mixers (average percentage increase in the productivities of the photobioreactor with static mixers over the productivities obtained without static mixers) was higher at higher standing biomass concentrations and on cloudy days (solar radiation below 6 MJ m(-2) day(-1)).     

Region-dependent oxygen transfer rate in the rectangular airlift reactor

Gas hold-up and the oxygen transfer in the zones of the internal loop airlift reactor with rectangular cross-section was studied. It was found, that the downcomer to the riser gas hold-up ratio depends on the gas flow rate, the physicochemical properties of the system and on the reactor height. The ratio of the downcomer mass transfer coefficient to the global mass transfer coefficient was less than 6%. The ratio of the downcomer to the global mass transfer coefficient slightly increased with increase of the gas flow rate and decreased with increase of the liquid viscosity. The proposed correlation for the global overall mass transfer coefficient predicts the experimental data well within 16.6% deviation. It was confirmed that the reactor height is the important parameter for a design and a scale-up of the airlift reactors.     

Mass transfer in a rectangular air-lift reactor: effects of geometry and gas recirculation

The interrelationships between the three parts of the air lift reactor, the riser, the downcomer, and gas-liquid separator, were examined with relation to the overall mass transfer in the reactor. This involved studying the mass transfer of oxygen from the gas phase to the liquid phase for 20 different reactor geometries. Both one- and two-sparger systems were studied. It was demonstrated that the gas-liquid separator plays a major role in reactor behavior and must be considered in reactor design. It was found that the overall reactor mass transfer coefficient KLA could be correlated to the pneumatic power of gas input per total dispersion volume (P/VD) and to the true riser superficial gas velocity JGR for all experimental conditions examined. The KLA is directly related to the P/VD with an exponent of approximately 1. "Two-sparger" systems, where an auxiliary gas sparger is placed near the downcomer entrance, have higher ab solute values for KLA than single-sparger systems.     

Characterization of a pilot plant airlift tower loop bioreactor. I: evaluation of the phase properties with model media

Investigations were carried out in a 9 m high, 4 m(3) volume, pilot plant airlift tower loop bioreactor with a draft tube. The reactor was characterized by measuring residence time distributions of the gas phase using pseudostochastic tracer signals and a mass spectrometer and by evaluating the mixing in the liquid phase with single-pulse tracer inputs. The local gas holdup and the bubble size (piercing length) were measured with two-channel electrical conductivity probes. The mean residence times and the intensities of the axial mixing in the riser and downcomer and the circulation times of the phases as well as the fraction of the recirculated gas phase were evaluated. The gas holdup in the riser is nearly uniform along the reactor. In the downcomer, it diminishes from top to bottom. The liquid phase dispersion coefficients, D(L), are smaller than those measured in the corresponding bubble columns. In the pilot plant with tap water the following relationship was found: D(Lr) = cw(SG) (n); with c = 203.4; n = 0.5;D(Lr)(cm(2) s(-1);) and W(SG)(cm s(-1)) where D(Lr) is the longitudinal dispersion coefficient in the riser and W(SG) is the superficial gas velocity. The gas phase dispersion coefficients in the riser of the pilot plant, D(Gr), are also enlarged with increasing superficial gas velocity, W(SG), however, no simple relationship exists. Parameter D(Gr) is the highest in the presence of antifoam agents, intermediate in tap water, and the smallest in ethanol solution.     

Gas holdup and overall volumetric oxygen transfer coefficient in airlift contactors

The two major types of airlift contactors, concentric-tube and external-loop, were investigated for their gas holdup (riser and downcomer) and overall mass transfer characteristics. Results obtained in batch charges of tap water and 0.15 kmol/m(3) NaCl solution are reported for external-loop airlift contactors having downcomer-to-riser cross-sectional area ratios, A(d)/A(r), ranging from 0.11 相似文献   

Membrane sparger in bubble column,airlift, and combined membrane–ring sparger bioreactors

The bubble column and the two internal loop airlift reactors (riser/downcomer area ratios of 0.11 and 0.58) characterized in this study were equipped with a rubber membrane sparger, which produced small bubbles, giving high mass transfer coefficients. The low mixing intensity in the bubble column was increased by an order of magnitude in the airlift reactors. We designed a novel aeration and mixing system by adding a ring sparger to the membrane sparger in the bubble column and maintained the advantages of both airlift configuration (good mixing properties) and bubble column configuration (efficient aeration, without any internal constructions). The combined membrane–ring sparger system has unique features with respect to the efficiency of utilization of substrate gasses and energy. Model experiments showed that the small bubbles from the membrane sparger do not coalesce with the large bubbles from the ring sparger. If different gases were added through the two spargers it was possible to transfer a hazardous or expensive gas quantitatively to the liquid through the membrane sparger (dual sparging mode). In the combined membrane–ring sparger system the energy input for mixing and mass transfer is divided. Therefore, the energy consumption can be minimized if the flow distribution of air through the membrane and ring sparger is controlled by the oxygen demand and the inhomogeneity of the culture, respectively (split sparging mode). The dual sparging mode was used for mass production of the alga Rhodomonas sp. as the first step in aquatic food chains. Avoiding mechanical parts removes an important risk of malfunction, and a continuous culture could be maintained for more than 8 months. © 1999 John Wiley & Sons, Inc. Biotechnol Bioeng 64: 452–458, 1999.     

Carbon monoxide mass transfer for syngas fermentation in a stirred tank reactor with dual impeller configurations

This study compares the power demand and gas-liquid volumetric mass transfer coefficient, kLa, in a stirred tank reactor (STR) (T = 0.211 m) using different impeller designs and schemes in a carbon monoxide-water system, which is applicable to synthesis gas (syngas) fermentation. Eleven different impeller schemes were tested over a range of operating conditions typically associated with the "after large cavity" region (ALC) of a Rushton-type turbine (D/T = 0.35). It is found that the dual Rushton-type impeller scheme exhibits the highest volumetric mass transfer rates for all operating conditions; however, it also displays the lowest mass transfer performance (defined as the volumetric mass transfer coefficient per unit power input) for all conditions due to its high power consumption. Dual impeller schemes with an axial flow impeller as the top impeller show improved mass transfer rates without dramatic increases in power draw. At high gas flow rates, dual impeller schemes with a lower concave impeller have kLa values similar to those of the Rushton-type dual impeller schemes but show improved mass transfer performance. It is believed that the mass transfer performance can be further enhanced for the bottom concave impeller schemes by operating at conditions beyond the ALC region defined for Rushton-type impellers because the concave impeller can handle higher gas flow rates prior to flooding.     

Concentric-tube airlift bioreactors

Gas holdup investigations were performed in three concentric-tube airlift reactors of different scales of operation (RIMP: 0.070 m³; RIS-1: 2.5 m³; RIS-2: 5.2 m³; nominal volumes). The influences of the top and bottom clearances and the flow resistances at the downcomer entrance were studied using tap water as liquid phase and air as gaseous phase, at atmospheric pressure. It was found that the gas holdup in the individual zone of the reactor: riser, downcomer and gas-separator, as well as that in the overall reactor is affected by the analyzed geometrical parameters in different ways, depending on their effects on liquid circulation velocity. Gas holdup was satisfactorily correlated with Fr, Ga, bottom spatial ratio (B), top spatial ratio (T), gas separation ratio (Y) and downcomer flow resistance ratio (A _d /A _R ). Correlations are presented for gas holdup in riser, downcomer, gas separator and for the total gas holdup in the reactor. All the above stressed the importance of the geometry in dynamic behaviour of airlift reactors.     

Design of static mixers for inclined tubular photobioreactors

Static mixers, which improve gas-liquid mass transfer inside tubular photobioreactors and move the cells between the upper and lower parts of the tubes were designed. Each static mixer was equipped with an opening (v-cut slit) at the top (for gas dispersion) and an orifice at the lower part (for liquid circulation). When the static mixers were installed in the riser tube of an inclined tubular photobioreactor, vertical movement of the liquid was induced so that cells were moved between the surface and bottom part of the photobioreactor. The mass transfer rates in the tubular photobioreactor without static mixers decreased sharply when they were scaled up by increasing the tube diameters. However, by installation of static mixers, the mass transfer rates in 12.5-cm diameter tubes were almost as high as those of 3.8-cm tubes without static mixers. The effectiveness of the static mixers in improving the mass transfer characteristics of the tubular photobioreactors was higher in large than small diameter tubes. The ratio of the diameters of the static mixers to the diameter of the tube, the areas of the v-cut slits and the orifice were the important design parameters that affected the mass transfer characteristics. The gas hold up and and k_La were higher when the areas of the slits (v-cut) and the orifice were reduced.     

Macromixing characteristics of gas-liquid jet loop reactors

Measurements of liquid macromixing characteristics are reported for a half industrial scaled jet loop reactor operating with air-water mixtures. Based on a model of loop reactors with sections of different mixing behavior the single circulation dispersion coefficient can be split into its components caused by the riser and the downcomer. The dispersion coefficient of the riser is about 100 times greater than that of the downcomer. The addition of gas involves greater dispersions coefficients. The comparison of the mixing times of the JLR with those of stirred vessels leads to the conclusion that the JLR is equivalent or even superior to stirred vessels.     

Concentric-tube airlift bioreactors

Liquid circulation velocity was investigated in three concentric-tube airlift reactors of different scales (RIMP, V _L =0.07 m³; RIS-1, V _L =2.5 m³; RIS-2, V _L =5.20 m³). The effects of top and bottom clearance and resistance in flow pathway at downcomer entrance on the riser liquid superficial velocity, the circulation time, the friction coefficient and flow radial profiles of the gas holdup and the liquid superficial velocity in riser, using water-air as a biphasic system, were studied. It was found that the riser liquid superficial velocity is affected by the analyzed geometrical parameters in different ways, depending on their effects on the pressure loss. The riser liquid superficial velocity, the friction coefficient and the parameters of the drift-flux model were satisfactorily correlated with the bottom spatial ratio (B), gas separation ratio (Y) and downcomer flow resistance ratio (A _d /A _D ), resulting empirical models, with correlation coefficients greater than 0.85.     

External-circulation-loop airlift bioreactors: study of the liquid circulating velocity in highly viscous non-Newtonian liquids

In order to obtain further information on the behavior and optimal design of external-circulation-loop airlift (ECL-AL) bioreactors, the liquid circulating velocity, gas holdup and average bubble diameter in the downcomer were studied using highly viscous pseudoplastic solutions of various types of CMC. A few comparative measurements also were made using a viscous Newtonian aqueous sucrose solution. For the liquid velocity measurements, an ultrasonic flow meter (Doppler frequency shift principle) was applied for the first time to the gas/non-Newtonian liquid dispersion in downward flow and satisfactory results were obtained. For viscous liquids, the circulating liquid velocity in the riser section of an ECL-AL (u(LR)) is shown to be dependent mainly on the downcomer-to-riser cross-sectional area ratio (A(d)/A(r)), the effective viscosity (eta(eff)) and the gas superficial velocity (u(GR)) as described by the following equation \documentclass{article}\pagestyle{empty}\begin{document}$$ u_{LR} = 0.23u_{GR};{0.32} (A_d /A_r);{0.97} \eta _{eff};{ - 0.39} $$\end{document} The circulating liquid velocity exerts opposing effects on the mass transfer and liquid-phase mixing performances of ECL-AL fermentors. Therefore, it is proposed that the optimum operating conditions for a given fermentation may be best achieved by means of independently regulating the circulating liquid velocity.     

Hydrodynamic study of an internal airlift reactor for microalgae culture

Internal airlift reactors are closed systems considered today for microalgae cultivation. Several works have studied their hydrodynamics but based on important solid concentrations, not with biomass concentrations usually found in microalgae cultures. In this study, an internal airlift reactor has been built and tested in order to clarify the hydrodynamics of this system, based on microalgae typical concentrations. A model is proposed taking into account the variation of air bubble velocity according to volumetric air flow rate injected into the system. A relationship between riser and downcomer gas holdups is established, which varied slightly with solids concentrations. The repartition of solids along the reactor resulted to be homogenous for the range of concentrations and volumetric air flow rate studied here. Liquid velocities increase with volumetric air flow rate, and they vary slightly when solids are added to the system. Finally, liquid circulation time found in each section of the reactor is in concordance with those employed in microalgae culture.     

Characterization of a pilot plant airlift tower loop bioreactor: II. Evaluation of global mixing properties of the gas phase during yeast cultivation

Saccharomyces cerevisiae was cultivated in a 4-m(3) pilot plant airlift tower loop reactor with a draft tube in batch and continuous operations and for comparison in a laboratory airlift tower loop reactor of 0.08 m(3) volume. The reactors were characterized during and after the cultivation by measuring the distributions of the residence times of the gas phase with pseudostochastic tracer signals and mass spectrometer and by evaluating the mixing in the liquid phase with a pulse-shaped volatile tracer signal and mass spectrometer as a detector. The mean residence times and the intensities of the axial mixing in the riser and downcomer, the circulation times of the gas phase, and the fraction of the recirculated gas phase were evaluated and compared.     

Distributed parameter model of an airlift fermentor

A distributed parameter model for an airlift fermentor is presented. A riser represents the airlift fermentor, with plug flow in both gas and liquid phases, a well-mixed section that acts as gas separator, and a downcomer with plug flow. The set of equations proposed makes possible both the understanding and design of the system. Macroscopic balances shows a behavior that is very close to conventional continuous stirred tank fermentor from the viewpoint of biomass production. In addition, the model predicts concentration profiles of biomass, substrate and oxygen in the liquid, and oxygen in the gas phase. This allows estimation of optimal gas flow rate for sufficient oxygen transfer with minimum energy input.     

Flow characteristics of a pilot-scale airlift fermentor

The effects of aeration on the flow characteristics of water in a glass pilot-scale airlift fermentor have been examined. The 55-L capacity fermentor consisted of a 15.2-cm-i.d. riser column with a 5.1-cm-i.d. downcomer tube. It was found that the average bubble size diminished with increased aeration. Typically, average bubble sizes ranged from 4.32 mm at a superficial gas velocity of 0.64 cm/s to 1.92 mm at 10.3 cm/s. A gas holdup of 0.19 was attained with superficial gas velocities (v_s) on the order of 10 cm/s, indicating the highly gassed nature of the fluid in the riser section of the fermentor. Circulation velocities of markers placed in the fermentor decreased with increasing aeration rates due to increased turbulence and axial liquid back mixing within the riser section. Actual volumetric liquid circulation rates remained relatively constant (0.36–0.49 L/s) for values of (v_s) up to 10 cm/s. Based on theoretical calculations, the ascending velocity of bubbles in a swarm reached 54 cm/s in the range of (v_s) values studied.