Revisiting the Effect of U-Bends, Flow Parameters, and Feasibility for Scale-Up on Residence Time Distribution Curves for a Continuous Bioprocessing Oscillatory Baffled Flow Reactor

An oscillatory baffled flow reactor (OBR) has been designed with 60 interbaffled cells. The baffled columns of 40 mm internal diameter together result in a reactor length of 5740 mm. The oscillatory amplitude and frequency were in the range of 2–12 mm and 0.3–2 Hz, respectively. The report investigates the impact of U-bends and the number of reactor sections on axial dispersion for scale-up feasibility. A prediction model using operating parameters has been developed to maximize plug flow conditions using the tanks-in-series (TiS) model. The maximum TiS value was 13.38 in a single column compared to 43.68 in the full reactor at a velocity ratio of 2.27 using oscillatory parameters 8 mm and 0.3 Hz. The mixing efficiency along the reactor was found to decrease after each column at amplitudes <6 mm compared to amplitudes up to 12 mm, where a negligible impact was observed. U-bend geometry had a significant role in the decrease of TiS values.

Optimal Operation of an Oscillatory Flow Crystallizer: Coupling Disturbance and Stability

In the process of industrial crystallization, it is always difficult to balance the secondary nucleation rate and metastable zone width (MSZW). Herein, we report an experimental and numerical study for the cooling crystallization of paracetamol in an oscillatory flow crystallizer (OFC), finding the optimal operating conditions for balancing the secondary nucleation rate and MSZW. The results show that the MSZW decreases with the increase of oscillation Reynolds number (Re _o). Compared to the traditional stirring system, the OFC has an MSZW three times larger than that of the stirring system under a similar power density of consumption. With the numerical simulation, the OFC can produce a stable space environment and instantaneous strong disturbance, which is conducive to the crystallization process. Above all, a high Re _o is favorable to produce a sufficient nucleation rate, which may inevitably constrict the MSZW to a certain degree. Then, the optimization strategy of the operating parameter (Re _o) in the OFC is proposed.

Crystallization of paracetamol from mixtures of ethanol and water in a planar oscillatory flow crystallizer: effect of the oscillation conditions on the crystal growth kinetics

Crystal growth kinetic data is reported for a planar oscillatory flow crystallizer.

The Hydrodynamics and Mixing Performance in a Moving Baffle Oscillatory Baffled Reactor through Computational Fluid Dynamics (CFD)

Oscillatory baffled reactors (OBRs) have attracted much attention from researchers and industries alike due to their proven advantages in mixing, scale-up, and cost-effectiveness over conventional stirred tank reactors (STRs). This study quantitatively investigated how different mixing indices describe the mixing performance of a moving baffle OBR using computational fluid dynamics (CFD). In addition, the hydrodynamic behavior of the reactor was studied, considering parameters such as the Q-criterion, shear strain rate, and velocity vector. A modification of the Q-criterion showed advantages over the original Q-criterion in determination of the vortices’ locations. The dynamic mesh tool was utilized to simulate the moving baffles through ANSYS/Fluent. The mixing indices studied were the velocity ratio, turbulent length scale, turbulent time scale, mixing time, and axial dispersion coefficient. We found that the oscillation amplitude had the most significant impact on these indices. In contrast, the oscillatory Reynolds number did not necessarily describe the mixing intensity of a system. Of the tested indices, the axial dispersion coefficient showed advantages over the other indices for quantifying the mixing performance of a moving baffle OBR.

Advanced reactor engineering with 3D printing for the continuous-flow synthesis of silver nanoparticles

3D printing has been employed to manufacture advanced reactor geometries based on miniaturised continuous-flow oscillatory baffled reactors (mCOBRs) and they have been applied for the fouling free continuous-flow synthesis of silver nanoparticles with optimal size control.

From discovery to scale-up: α-lipoic acid : nicotinamide co-crystals in a continuous oscillatory baffled crystalliser

Discovery, characterisation and scale-up of novel α-lipoic acid co-crystals using continuous crystallisation in a COBC is demonstrated.

Biological processing in oscillatory baffled reactors: operation, advantages and potential

The development of efficient and commercially viable bioprocesses is essential for reducing the need for fossil-derived products. Increasingly, pharmaceuticals, fuel, health products and precursor compounds for plastics are being synthesized using bioprocessing routes as opposed to more traditional chemical technologies. Production vessels or reactors are required for synthesis of crude product before downstream processing for extraction and purification. Reactors are operated either in discrete batches or, preferably, continuously in order to reduce waste, cost and energy. This review describes the oscillatory baffled reactor (OBR), which, generally, has a niche application in performing 'long' processes in plug flow conditions, and so should be suitable for various bioprocesses. We report findings to suggest that OBRs could increase reaction rates for specific bioprocesses owing to low shear, good global mixing and enhanced mass transfer compared with conventional reactors. By maintaining geometrical and dynamic conditions, the technology has been proved to be easily scaled up and operated continuously, allowing laboratory-scale results to be easily transferred to industrial-sized processes. This is the first comprehensive review of bioprocessing using OBRs. The barriers facing industrial adoption of the technology are discussed alongside some suggested strategies to overcome these barriers. OBR technology could prove to be a major aid in the development of commercially viable and sustainable bioprocesses, essential for moving towards a greener future.