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    Bioreactor Design

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    myself_ritesh
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    Bioreactor Design

    Uploaded by

    myself_ritesh
    4 views31 pages
    bioreactor design

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    bioreactor design

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    bioreactor design

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    4 views31 pages

    Bioreactor Design

    Uploaded by

    myself_ritesh
    bioreactor design

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 31

    1(31)

    Finmed 2006, March 27-31,


    Saariselkä, Finland

    CHEMICAL ENGINEERING ASPECTS


    OF BIOREACTOR DESIGN
    Marko Laakkonen, Pasi Moilanen, Olli Visuri,
    Juhani Aittamaa

    Laboratory of Chemical Engineering


    Helsinki University of Technology
    Finland
    2(31)

    NEW DESIGN TOOL FOR BIOREACTORS


    (2004–2005), NEOBIO,

    TKK, Lab. of applied


    thermodynamics
    3(31)

    OUTLINE
    1. Motivation
    2. Modelling transport phenomena in agitated,
    aerobic fermenters
    3. Model validation against experiments
    3.1 Mixing times & Flow fields
    3.2 Bubble size distributions
    3.3 Gas-liquid mass transfer
    4. Bioreactor simulations
    4.1 Effects of mixing on xanthan fermentation dynamics
    4.2 Simulating 70 m3 xanthan fermenter with CFD
    5. Conclusions
    4(31)

    AEROBIC FERMENTATION
    fermentation broth

    BUBBLE nutrients,
    substrates,...
    O2 O2

    CO2
    products CELL
    5(31)

    REACTOR SCALEUP
    r t a nt
    g l y impo
    i n
    i nc r ea s
    com e
    na be
    o me
    ort phen
    s p
    T ran

    Mixing, mass and heat


    transfer limitations?
    6(31)
    TYPICAL QUESTIONS RELATED TO
    REACTOR DESIGN
    mixing
    Is there enough dissolved
    oxygen?
    Are oxygen and nutrients
    evenly distributed?
    A damage of microbial
    growth due to mechanical
    agitation?
    Agitation speed?
    Gas feed rate?
    Vessel geometry?
    gas sparger
    7(31)

    CRITICAL PHENOMENA FOR


    REACTOR OPERATION?
    Flow fields TRANSPORT
    Population
    Mass transfer PHENOMENA
    balances
    Heat transfer
    Physical
    properties
    Design &
    scaleup

    Reaction REACTOR
    Laboratory kinetics MODEL
    Experiments
    8(31)

    GAS-LIQUID MASS TRANSFER

    RATE = FLUX × AREA


    Two-film theory, Population
    multicomponent balances for
    diffusion, gas- bubbles (size
    liquid equilibrium distributions)
    9(31)

    BUBBLE PHENOMENA
    coalescence

    growth
    breakage

    bubble slip
    velocity
    10(31)
    REACTOR MODELLING -
    Computational Fluid Dynamics (CFD)
    Solve mass, momentum
    balances & turbulence
    Î Flow fields
    11(31)

    MULTIBLOCK REACTOR MODEL


    Consists of
    ideally mixed,
    connected
    subregions

    Considers
    dispersion
    Inhomogeneity

    Computationally efficient
    12(31)
    EXPERIMENTAL VALIDATION OF
    Model system: MODELS
    Aqueous xanthan 200 dm3
    Investigated quantities: stirred tank
    Liquid viscosity
    Power consumption
    Overall gas holdup
    Local bubble size distributions
    Gas-liquid mass transfer
    Flow fields & mixing times
    Variables:
    Stirring speed (0.1 – 3 W/kg)
    Gassing rate (0 – 0.9 vvm)
    Xanthan concentration
    Vessel geometry
    13(31)

    VISCOSITY MEASUREMENTS
    200
    xanthan conc.
    180 0.25 w-%
    0.50 w-%
    160
    1.0 w-% measured
    2.0 w-%
    4.0 w-%
    140 0.25 w-%
    0.50 w-% fitted

    viscosity (Pas)
    120 1.0 w-%
    2.0 w-% model
    tähän kuva 100 4.0 w-%

    80 τ yield
    µ eff = + kγ n −1
    60 γ
    40

    20

    0
    0.1 1.0 10.0
    shear rate (1/s)
    14(31)

    FLOW FIELDS
    CFD simulation PIV measurements
    Cavern 0.5 m/s
    Formation

    Impeller tip speed 1.35 m/s, 0.4 w-% xanthan solution


    15(31)

    MIXING TIME MEASUREMENTS

    0.25 w-% xanthan 2 w-% xanthan


    16(31)

    BUBBLE SIZE MEASUREMENT

    Capillary probe
    Phase Doppler
    Anemometry (PDA)

    30 mm
    45 mm

    Photography
    Optical probe
    LOCAL BUBBLE SIZE DISTRIBUTIONS 17(31)

    AIR – WATER
    d32 [mm]

    measured
    D E multiblock
    (CFD)

    C
    impeller

    measured A
    ideally mixed
    multiblock
    CFD(32k) gas sparger
    18(31)
    LOCAL BUBBLE SIZE DISTRIBUTIONS
    AIR – AQUEOUS XANTHAN

    d32 = 8.1 7.8


    8.0 mm

    4.9
    [2.3] 6.2 6.7
    xanthan
    3.1
    [2.6] 4.2 4.8

    1.3*/ 3.9#/
    2.1 1.3 5.8
    [2.0] 1.8

    3.0 4.3
    3.3 3.7
    [2.8]
    sparger

    Markers = Measured
    0mm 3.6
    22mm 3.7
    Lines = Simulated
    19(31)

    EFFECT OF STIRRING SPEED


    BUBBLE GAS
    SIZE HOLDUP

    2 w-% GAS FEED


    aqueous 0.7 vvm
    xanthan
    20(31)

    EFFECT OF GAS FEED


    BUBBLE GAS
    SIZE HOLDUP

    2 w-% STIRRING
    aqueous SPEED
    xanthan 390 rpm
    21(31)
    SIMULATION OF GAS-LIQUID
    HYDRODYNAMICS WITH CFD
    0.25 w-%
    xanthan
    390 rpm
    0.7 vvm

    gas holdup
    10 vol-%
    isosurface
    22(31)

    GAS-LIQUID MASS TRANSFER


    varying
    gas feeds 0.25 w-%
    & stirring xanthan
    speeds

    0.0 w-%

    Markers =
    measured
    0.25 w-%
    Lines =
    0.75 w-% multiblock
    simulation
    23(31)

    PREDICTED LOCAL kLa [·103 s-1]


    0 w-% xanthan 0.25 w-% xanthan 0.75 w-% xanthan
    k L a' = 0.0073 s −1 k L a' = 0.0015 s −1

    impeller impeller impeller

    sparger sparger sparger


    24(31)
    EFFECTS OF MIXING ON XANTHAN
    FERMENTATION DYNAMICS
    300 rpm
    350 rpm S2
    S2
    400 rpm
    450 rpm
    475 rpm S1

    S1, 300 rpm

    S2, xanthan
    S2
    S1, xanthan

    S1 & S2, biomass S1


    25(31)

    LOCAL CONDITIONS IN THE FERMENTER


    Bubble size Mass transfer Diss. oxygen Reaction rate
    d32 [mm] kLa’ [103/s] DO [sat-%] rX [gX/L/h
    26(31)
    DISTRIBUTION OF NUTRIENT
    PULSE IN 70 M3 FERMENTER
    BAFFLES

    RUSHTON
    IMPELLERS

    GAS FEED
    27(31)

    DISTRIBUTION OF GAS PULSE


    IN 70 M3 FERMENTER
    1s 3s 5s 10 s 20 s 30 s
    28(31)

    DISSOLVED GASES
    IN 70 m3 XANTHAN FERMENTER
    DO2 DCO2
    [mg/L] [mg/L]
    LOCAL CONDITIONS 29(31)

    IN 70 M3 XANTHAN FERMENTER
    Xanthan
    kLa [s-1]
    Reaction
    rate [g/(L•h)]
    30(31)

    CONCLUSIONS

    Physical reactor modeling provides


    • means to see ’inside’ industrial
    bioreactors
    • tools for
    Reactor design and scaleup
    Production planning and optimisation
    Trouble-shooting
    31(31)

    CONCLUSIONS

    Mixing, mass and heat transfer


    often important in all scales

    Detailed reactor studies can be


    made based on simple physical
    property measurements

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