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.     

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.     

Characterization of a pilot plant airlift tower loop reactor: III. Evaluation of local properties of the dispersed gas phase during yeast cultivation and in model media

The local properties of the dispersed gas phase (gasholdup, bubble diamater, and bubble velocity) were measured and evaluated at different positions in the riser and downcomer of a pilot plant reactor and, for comparison, in a laboratory reactor. These were described in Parts I and II of this series of articles during yeast cultivation and with model media. In the riser of the pilot plant reactor, the local gas holdup and bubble velocities varied only slightly in axial direction. The gas holdup increased considerably, while the bubble velocity increased only slightly with aeration rate. The bubble size diminished with increasing distance from the aerator in the riser, since the primary bubble size was larger than the equilibrium bubble size. In the downcomer, the mean bubble size was smaller than in the riser. The mean bubble size varied only slightly, the bubble velocity was accelerated, and the gas holdup decreased from top to bottom in the downcomer. In pilot plant at constant aeration rate, the properties of the dispersed phase were nearly constant during the batch cultivation, i.e., they depended only slightly on the cell concentration. In the laboratory reactor, the mean bubble sizes were much larger than in the pilot plant reactor. In the laboratory reactor, the bubble velocities in the riser and downcomer increased, and the mean gas holdup and bubble diameter in the downcomer remained constant as the aeration rate was increased.     

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 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.     

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.     

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.     

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.     

Biomass axial distribution in airlift bioreactor with yeast and plant cells

This study was aimed at determining the degree of biomass homogeneity in the various parts of an internal loop airlift bioreactor, thus verifying the assumption, often made in bioreactor studies, of a well-mixed liquid-biomass system. Following characterization of the hydrodynamics of the vessel with water, the axial biomass distribution in the riser and downcomer was determined for plant and yeast cell suspensions of 5.8, 8.5, and 12.5 g DW/L Phaseolus vulgaris and of 30 and 46 g DW/L Saccharomyces cerevisiae. The airlift bioreactor with a surface ratio A(D)/A(D) of 1.04 and aspect ratio of 4.95 was investigated under various aeration rates. The yeast cells were found to be distributed practically uniformly throughout the vessel at the aeration rates of 0.1-1.45 vvm. However, in the case of the denser and cluster-forming plant cells, a clear trend of a gradual bio-mass accumulation in the downcomer, a slightly lower but uniform biomass loading in the riser, and a slightly higher biomass concentration in the gas-liquid separator was observed at the lower aeration rates of 0.1-0.61 vvm. In the case of powderized calcium carbonate (55g/L) often used in fermentations of organic acids, a slight trend of a gradual accumulation of solids towards the bottom parts in both the downcomer and riser was observed. A better representative sampling location, in terms of solids and biomass loading, seems to be in the middle part of the vessel. It is suggested that airlift bioreactors with higher aspect ratios (>5) may be prone to a more significant inhomogeneity of solids (biomass and particles).     

Influence of reactor geometry on mixing characteristics in a down flow jet loop bioreactor: newtonian and non-newtonian fluids

Mixing characteristics in the downcomer and the riser of a continuous down-flow jet loop bioreactor was studied with Newtonian and non-Newtonian fluids. The mixing parameters were determined through the curve fitting of the experimental impulse response data with the solution of one dimensional axial dispersion model. It was found that circulation number and axial dispersion coefficient increased with an increase in liquid flow rate and draft tube to column diameter ratio and the axial dispersion coefficient was comparatively higher in the riser. The circulation number increased with decrease in nozzle diameter. The model predicted the experimental data well within 8% deviation for both the systems (water and CMC). Correlations were obtained to predict axial dispersion coefficients in the riser and downcomer of the reactor.     

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.     

The scale-up of plant cell culture: Engineering considerations

The enormous versatility of plants has continued to provide the impetus for the development of plant tissue culture as a commercial production strategy for secondary metabolites. Unfortunately problems with slow growth rates and low products yields, which are generally non-growth associated and intracellular, have made plant cell culture-based processes, with a few exceptions, economically unrealistic. Recent developments in reactor design and control, elicitor technology, molecular biology, and consumer demand for natural products, are fuelling a renaissance in plant cell culture as a production strategy. In this review we address the engineering consequences of the unique characteristics of plant cells on the scale-up of plant cell culture.Abbreviations a gas-liquid interfacial area per volume - C dissolved oxygen concentration - C^* liquid phase oxygen concentration in equilibrium with the partial pressure of oxygen in the bulk gas phase - K_L overall mass transfer coefficient - k_L liquid film mass transfer coefficient - m_O2 cell maintenance coefficient for oxygen - OTR oxygen transfer rate - OUR oxygen uptake rate - pO₂ partial pressure of oxygen - STR stirred-tank reactor - v.v.m. volume of gas fed per unit operating volume of reactor per minute - X biomass concentration - Y_x/O2 biomass yield coefficient for oxygen - specific growth rate     

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   

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.     

Generation of small bubbles and small bubble-liquid mass transfer in airlift reactors containing highly viscous liquids

The time-dependent gas hold-up is investigated during the aeration of the Saccharomyces cerevisiae suspension, the aqueous saccharose solutions and the glycerol solutions in the external loop airlift reactor. Due to the time-dependent bubble size distribution the fraction of the small bubble hold-up in the total gas hold-up decreases with an increase of the gas flow rate and with a decrease of the viscosity. The course of the accumulation process of the small bubbles is described by the first-order kinetic equation. The small bubble accumulation rate is investigated in the airlift reactor and the bubble column. It is showed that the small bubbles form and disappear exclusively in the riser of the airlift reactor. It is found that the small bubble-liquid mass transfer coefficient is several times larger than the overall oxygen transfer coefficient.     

Two- and three-phase mixing in a concentric draft tube gas-lift fermentor

Two- and three-phase mixing studies were carried out in a 44-L concentric draft tube gas-lift fermentor. It was proposed to use the fermentor for the production of solvents using immobilized bacteria. Bubble size, gas holdup, liquid velocities, circulation, and mixing times were determined for various superficial gas velocities in distilled water, starch, carboxymethyl cellulose, and ethanol solutions. The observed trends for two phase mixing were similar to other studies but the results were found to be more sensitive to liquid properties. This was possibly due to the large value of downcomer to riser area used in this study. Mixing in three phases highlighted the difficulty in predicting the effect of adding solids to the gas-liquid system. Results showed that the gas-lift fermentor was ideally suited to dealing with three phases but more work is necessary before accurate models can be developed to account for the effect of solids.     

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.     

Enhancement of oxygen transfer in highly viscous non-newtonian fermentation broths

The influence of short draft tubes covered by perforated plates on gas-liquid mass transfer was examined in external-loop airlift bioreactors. The volumetric mass transfer coefficients in a model external-loop airlift bioreactor were measured with water and non-Newtonian media. It was found that introduction of draft tubes covered with perforated plates in the riser significantly improved the mass transfer rate, particularly in higher viscous non-Newtonian fermentation media. The enhancement of mass transfer rate might be due mainly to an increase in bubble coalescence and redispersion. (c) 1994 John Wiley & Sons, Inc.