Validation of computational fluid dynamics of shake flask experiments at moderate viscosity by liquid distributions and volumetric power inputs

Computational fluid dynamics (CFD) has recently become a pivotal tool in the design and scale-up of bioprocesses. While CFD has been extensively utilized for stirred tank reactors (STRs), there exists a relatively limited body of literature focusing on CFD applications for shake flasks, almost exclusively concentrated on fluids at waterlike viscosity. The importance of CFD model validation cannot be overstated. While techniques to elucidate the internal flow field are necessary for model validation in STRs, the liquid distribution, caused by the orbital shaking motion of shake flasks, can be exploited for model validation. An OpenFOAM CFD model for shake flasks has been established. Calculated liquid distributions were compared to suitable, previously published experimental data. Across a broad range of shaking conditions, at waterlike and moderate viscosity (16.7 mPa∙s), the CFD model's liquid distributions align excellently with the experimental data, in terms of overall shape and position of the liquid relative to the direction of the centrifugal force. Additionally, the CFD model was used to calculate the volumetric power input, based on the energy dissipation. Depending on the shaking conditions, the computed volumetric power inputs range from 0.1 to 7 kW/m3 and differed on average by 0.01 kW/m3 from measured literature data.

Investigation of the Role of Impeller Structural Parameters on Liquid-Liquid Mixing Characteristics in Stirred Tanks

Liquid-liquid mixings in stirred tanks are commonly found in many industries. In this study, we performed computational fluid dynamics (CFD) modeling and simulation to investigate the liquid-liquid mixing behavior. Furthermore, the population balance model (PBM) was used to characterize the droplet size distribution. The PBM model parameters were calibrated using the experimental data of droplet sizes at different agitation speeds. Additionally, we employed the steady-state Sauter mean droplet size to validate the developed CFD-PBM coupled model at different dispersion phase holdups. Then, the validated CFD-PBM coupled model was employed to evaluate the role of impeller structural parameters on the liquid-liquid mixing efficiency based on a user-defined mixing index. It was found that the position of impellers significantly affects the mixing efficiency, and an increase in stirring speed and the number of impellers improved the mixing efficiency.

Temporary immersion systems (TISs): A comprehensive review

The temporary immersion systems (TISs) have been widely used in plant biotechnology. TISs have different advantages from the point of micropropagation and production of secondary metabolites over other continuous liquid-phase bioreactors. The current work presents the structure, operation mode, configuration type, and micropropagation or secondary metabolite production in TISs. This review deals with the advantages and disadvantages of TISs and the factors affecting their performance. Future research could focus on new designs based on CFD simulation, facilitating sterilization, and combining TISs with other bioreactors (e.g., mist bioreactors) to make a hybrid bioreactor.

Cultivating Multidisciplinarity: Manufacturing and Sensing Challenges in Cultured Meat Production

Meat cultivation via cellular agriculture holds great promise as a method for future food production. In theory, it is an ideal way of meat production, humane to the animals and sustainable for the environment, while keeping the same taste and nutritional values as traditional meat and having additional benefits such as controlled fat content and absence of antibiotics and hormones used in the traditional meat industry. However, in practice, there is still a number of challenges, such as those associated with the upscale of cultured meat (CM). CM food safety monitoring is a necessary factor when envisioning both the regulatory compliance and consumer acceptance. To achieve this, a multidisciplinary approach is necessary. This includes extensive development of the sensitive and specific analytical devices i.e., sensors to enable reliable food safety monitoring throughout the whole future food supply chain. In addition, advanced monitoring options can help in the further optimization of the meat cultivation which may reduce the currently still high costs of production. This review presents an overview of the sensor monitoring options for the most relevant parameters of importance for meat cultivation. Examples of the various types of sensors that can potentially be used in CM production are provided and the options for their integration into bioreactors, as well as suggestions on further improvements and more advanced integration approaches. In favor of the multidisciplinary approach, we also include an overview of the bioreactor types, scaffolding options as well as imaging techniques relevant for CM research. Furthermore, we briefly present the current status of the CM research and related regulation, societal aspects and challenges to its upscaling and commercialization.

Application of CFD to Analyze the Hydrodynamic Behaviour of a Bioreactor with a Double Impeller

Stirred bioreactors are commonly used unit operations in the pharmaceutical industry. In this study, computational fluid dynamics (CFD) was used in order to analyze the influence of the impeller configuration (Segment–Segment and Segment–Rushton impeller configurations) and the impeller rotational speed (an operational parameter) on the hydrodynamic behaviour and mixing performance of a bioreactor equipped with a double impeller. A relatively close agreement between the power values obtained from the CFD model and those measured experimentally was observed. Various parameters such as velocity profiles, stress generated by impellers due to the turbulence and velocity gradient, flow number, and mixing time were used to compare the CFD simulations. It was observed that the impeller’s RPM could change the intensity of the interaction between the impellers when a Segment–Rushton impeller was used. In general, increasing the RPM led to an increase in total power and the stress acting on the cells and to a shorter mixing time. At a constant RPM, the Segment–Rushton impeller configuration had higher total power and stress acting on cells compared to the Segment–Segment impeller configuration. At lower RPM values (i.e., 50 and 100), the Segment–Segment impeller provided a shorter mixing time. Conversely, at the highest RPM (i.e., 150) the Segment–Rushton impeller had a shorter mixing time compared to the Segment–Segment impeller; this was attributed to the high level of turbulence generated with the former impeller configuration at high RPM.

Experimentally Validated CFD Model for Gas-Liquid Flow in a Round-Bottom Stirred Tank Equipped with Rushton Turbine

Hydrodynamics of gas-liquid flow in a round-bottom stirred tank is modelled at two gas flow rates, constant bubble size and agitator speed of 300 rpm. A round-bottom tank equipped with four baffles and a Rushton turbine was chosen to represent a typical reactor used in hydrometallurgical processes operating under pressure. The applicability of different momentum interchange models and the Realizable k-ε, SST k-ω, and RSM turbulence models was studied using CFD software. The results were compared and validated against experimental data from Particle Image Velocimetry measurements by means of liquid and gas velocity distributions. In addition, energy balance between power input and dissipation energy was compared for the different turbulence models. The CFD model was found to be in good agreement with the measurements. Of the turbulence models studied, the Realizable k-ε model showed best agreement with the measured velocity profiles. Popular drag force models proposed in the literature were assessed, as was the influence of inclusion of non-drag forces. Gas flow was found to affect the liquid phase flow in the tank by generating an additional secondary circulation loop in the upper part of the reactor.

Investigating the effect of sparger configuration on the hydrodynamics of a full-scale membrane bioreactor using computational fluid dynamics

A three-phase computational fluid dynamics (CFD) simulation was carried out in a full-scale membrane bioreactor to investigate the effect of sparger configuration on various hydrodynamic parameters.