On the quantification of energy dissipation in the impeller stream of a stirred vessel from fluctuating velocity gradient measurements

Flow characteristics of the Rushton and pitched blade turbines in turbulent and laminar mixing

The velocity field and concentration distribution of three radial and axial impellers were studied in miscible liquid blending in a stirred tank reactor. To obtain a better insight into the applicability of each impeller system, the influence of velocity profiles on the generated concentration profiles was studied in detail for each impeller. Particle image velocimetry (PIV) and planar laser induced fluorescence (PLIF) methods were used as the measurement techniques. In the turbulent regime, the Rushton turbine provided a homogeneous concentration field throughout the reactor by generating high radial and axial velocities in the bottom and upper zones of the tank. Operation comparisons of the up and down-pumping pitched blade turbines illustrated that the up-pumping turbine had a better performance in overall because of producing high turbulence in the upper half of the reactor. In this region, the radial concentration profile approached the final homogenized value in a shorter time. In the laminar regime, all three impellers acted in a similar way and produced a radial flow throughout the reactor.

Characterization of the Metabolic Response of Streptomyces clavuligerus to Shear Stress in Stirred Tanks and Single-Use 2D Rocking Motion Bioreactors for Clavulanic Acid Production

Streptomyces clavuligerus is a gram-positive filamentous bacterium notable for producing clavulanic acid (CA), an inhibitor of β-lactamase enzymes, which confers resistance to bacteria against several antibiotics. Here we present a comparative analysis of the morphological and metabolic response of S. clavuligerus linked to the CA production under low and high shear stress conditions in a 2D rocking-motion single-use bioreactor (CELL-tainer ^®) and stirred tank bioreactor (STR), respectively. The CELL-tainer^® guarantees high turbulence and enhanced volumetric mass transfer at low shear stress, which (in contrast to bubble columns) allows the investigation of the impact of shear stress without oxygen limitation. The results indicate that high shear forces do not compromise the viability of S. clavuligerus cells; even higher specific growth rate, biomass, and specific CA production rate were observed in the STR. Under low shear forces in the CELL-tainer^® the mycelial diameter increased considerably (average diameter 2.27 in CELL-tainer^® vs. 1.44 µm in STR). This suggests that CA production may be affected by a lower surface-to-volume ratio which would lead to lower diffusion and transport of nutrients, oxygen, and product. The present study shows that there is a strong correlation between macromorphology and CA production, which should be an important aspect to consider in industrial production of CA.

The Influence of Internal Intermittency, Large Scale Inhomogeneity, and Impeller Type on Drop Size Distribution in Turbulent Liquid-Liquid Dispersions

The influence of the impeller type on drop size distribution (DSD) in turbulent liquid-liquid dispersion is considered in this paper. The effects of the application of two impellers, high power number, high shear impeller (six blade Rushton turbine, RT) and three blade low power number, and a high efficiency impeller (HE3) are compared. Large-scale and fine-scale inhomogeneity are taken into account. The flow field and the properties of the turbulence (energy dissipation rate and integral scale of turbulence) in the agitated vessel are determined using the k-ε model. The intermittency of turbulence is taken into account in droplet breakage and coalescence models by using multifractal formalism. The solution of the population balance equation for lean dispersions (when the only breakage takes place) with a dispersed phase of low viscosity (pure system or system containing surfactant), as well as high viscosity, show that at the same power input per unit mass HE3 impeller produces much smaller droplets. In the case of fast coalescence (low dispersed phase viscosity, no surfactant), the model predicts similar droplets generated by both impellers. In the case of a dispersed phase of high viscosity, when the mobility of the drop surface is reduced, HE3 produces slightly smaller droplets.

Local Turbulent Energy Dissipation Rate in a Vessel Agitated by a Rushton Turbine

The scaling of turbulence characteristics such as turbulent fluctuation velocity, turbulent kinetic energy and turbulent energy dissipation rate was investigated in a mechanically agitated vessel 300 mm in inner diameter stirred by a Rushton turbine at high Reynolds numbers in the range 50 000 < Re < 100 000. The hydrodynamics and flow field was measured using 2-D TR PIV. The convective velocity formulas proposed by Antonia et al. (1980) and Van Doorn (1981) were tested. The turbulent energy dissipation rate estimated independently in both radial and axial directions using the one-dimensional approach was not found to be the same in each direction. Using the proposed correction, the values in both directions were found to be close to each other. The relation ε/(N3·D2) ∞ const. was not conclusively confirmed.

Characterization of hydromechanical stress in aerated stirred tanks up to 40 m(3) scale by measurement of maximum stable drop size

BACKGROUND

Turbulence intensity, or hydromechanical stress, is a parameter that influences a broad range of processes in the fields of chemical engineering and biotechnology. Fermentation processes are often characterized by high agitation and aeration intensity resulting in high gas void fractions of up to 20% in large scale reactors. Very little experimental data on hydromechanical stress for such operating conditions exists because of the problems associated with measuring hydromechanical stress under aeration and intense agitation.

RESULTS

An indirect method to quantify hydromechanical stress for aerated operating conditions by the measurement of maximum stable drop size in a break-up controlled dispersion was applied to characterize hydromechanical stress in reactor scales of 50 L, 3 m(3) and 40 m(3) volume with a broad range of operating conditions and impeller geometries (Rushton turbines). Results for impellers within each scale for the ratio of maximum to specific energy dissipation rate ϕ based on measured values of maximum stable drop size for aerated operating conditions are qualitatively in agreement with results from literature correlations for unaerated operating conditions. Comparison of data in the different scales shows that there is a scale effect that results in higher values for ϕ in larger reactors. This behavior is not covered by the classic theory of turbulent drop dispersion but is in good agreement with the theory of turbulence intermittency. The data for all impeller configurations and all aeration rates for the three scales can be correlated within ±20% when calculated values for ϕ based on the measured values for dmax are used to calculate the maximum local energy dissipation rate. A correlation of the data for all scales and all impeller configurations in the form ϕ = 2.3∙(ϕunaerated)(0.34)∙(DR)(0.543) is suggested that successfully models the influence of scale and impeller geometry on ϕ for aerated operating conditions.

CONCLUSIONS

The results show that besides the impeller geometry, also aeration and scale strongly influence hydromechanical stress. Incorporating these effects is beneficial for a successful scale up or scale down of this parameter. This can be done by applying the suggested correlation or by measuring hydromechanical stress with the experimental method used in this study.

On the fluid dynamics of a laboratory scale single-use stirred bioreactor

The commercial success of mammalian cell-derived recombinant proteins has fostered an increase in demand for novel single-use bioreactor (SUB) systems that facilitate greater productivity, increased flexibility and reduced costs (Zhang et al., 2010). These systems exhibit fluid flow regimes unlike those encountered in traditional glass/stainless steel bioreactors because of the way in which they are designed. With such disparate hydrodynamic environments between SUBs currently on the market, traditional scale-up approaches applied to stirred tanks should be revised. One such SUB is the Mobius^® 3 L CellReady, which consists of an upward-pumping marine scoping impeller. This work represents the first experimental study of the flow within the CellReady using a Particle Image Velocimetry (PIV) approach, combined with a biological study into the impact of these fluid dynamic characteristics on cell culture performance. The PIV study was conducted within the actual vessel, rather than using a purpose-built mimic. PIV measurements conveyed a degree of fluid compartmentalisation resulting from the up-pumping impeller. Both impeller tip speed and fluid working volume had an impact upon the fluid velocities and spatial distribution of turbulence within the vessel. Cell cultures were conducted using the GS-CHO cell-line (Lonza) producing an IgG₄ antibody. Disparity in cellular growth and viability throughout the range of operating conditions used (80-350 rpm and 1-2.4 L working volume) was not substantial, although a significant reduction in recombinant protein productivity was found at 350 rpm and 1 L working volume (corresponding to the highest Reynolds number tested in this work). The study shows promise in the use of PIV to improve understanding of the hydrodynamic environment within individual SUBs and allows identification of the critical hydrodynamic parameters under the different flow regimes for compatibility and scalability across the range of bioreactor platforms.

Minimizing hydrodynamic stress in mammalian cell culture through the lobed Taylor-Couette bioreactor

The objective of the present study was to investigate the effect of hydrodynamic stress heterogeneity on metabolism and productivity of an industrial mammalian cell line. For this purpose, a novel Lobed Taylor-Couette (LTC) mixing unit combining a narrow distribution of hydrodynamic stresses and a membrane aeration system to prevent cell damage by bubble bursting was developed. A hydrodynamic analysis of the LTC was developed to reproduce, in a uniform hydrodynamic environment, the same hydrodynamic stress encountered locally by cells in a stirred tank, particularly at the large scale, e.g., close and far from the impeller. The developed LTC was used to simulate the stress values near the impeller of a laboratory stirred tank bioreactor, equal to about 0.4 Pa, which is however below the threshold value leading to cell death. It was found that the cells actively change their metabolism by increasing lactate production and decreasing titer while the consumption of the main nutrients remains substantially unchanged. When considering average stress values ranging from 1 to 10 Pa found by other researchers to cause physiological response of cells to the hydrodynamic stress in heterogeneous stirred vessels, our results are close to the lower boundary of this interval.