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Fluid Flow and Mixing

This document discusses fluid flow and mixing in bioreactors. It covers topics like power requirements for mixing Newtonian and non-Newtonian fluids in gassed and ungassed systems. It also discusses scale-up issues, adapting bioreactor design to enhance mixing, and the effect of fluid rheology and shear on mixing and cell damage in bioprocesses.

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176 views

Fluid Flow and Mixing

This document discusses fluid flow and mixing in bioreactors. It covers topics like power requirements for mixing Newtonian and non-Newtonian fluids in gassed and ungassed systems. It also discusses scale-up issues, adapting bioreactor design to enhance mixing, and the effect of fluid rheology and shear on mixing and cell damage in bioprocesses.

Uploaded by

vikichopda
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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FLUID FLOW AND MIXING IN BIOREACTORS

(Part 2 of 2)

Overview
Power requirements for mixing
Newtonian and non-Newtonian liquids Ungassed and gassed systems

Scale-up issues, scale-down approach Adapting bioreactor design to enhance mixing Effect of fluid rheology on mixing Shear in stirred bioreactors Shear damage to cells in bioprocesses

Mixing power (ungassed Newtonian fluids)


depends on
impeller geometry, size and rotation speed Fluid density and viscosity

Power relationships expressed in terms of


P Dimensionless Power No. (Np): N p = N i3 Di5 P = power; = liquid density;
Di = impeller diameter; Ni = rotation speed

Mixing power (ungassed Newtonian fluids)

1! Rushton turbine; 2! Paddle;

3! Marine propeller

Mixing power (ungassed Newtonian fluids)

Mixing power (ungassed Newtonian fluids)

1! Anchor impeller

2! Helical ribbon impeller

Mixing power (ungassed Newtonian fluids)

Mixing power (ungassed Newtonian fluids)


Power requirement is calculated from: P = N p N i3 Di5 or, P = k N i Di For fully turbulent conditions, Np is constant
1

1 For Rei in the laminar range, N p Rei 2 3

N p = N 'p

In the transition region, Np is obtained from the graph

Mixing power (ungassed non-Newtonian fluids)

Mixing power (ungassed non-Newtonian fluids)


For Rei < 10 and Rei > 100, Np is the same as for Newtonian fluids For 10 < Rei < 100, power absorption less than in Newtonian fluids Apparent viscosity values to be used in Reynolds No. calculation Difficulties in estimating power due to variation in viscosity
with position in the fermenter with fermentation time

Effect of gas sparging on mixing power


Power consumption less with gas sparging due to
reduced average liquid density gas cavities behind stirrer blades (less fluid resistance)

Effect of gas sparging on mixing power


An approximate expression for reduced power requirement is
Pg Fg = 0.1 NV P0 i
0.25

N D gW V 2 3 i
2 i 4 i

0.20

Pg = gassed power; P0 = ungassed power Fg = volumetric gas flow rate; Wi = impeller blade width V = liquid volume

The reduction in power absorption not uniform because gas cavity formation is random

Scale-up of mixing
Scale-up :
development of production scale bioreactor design specifications based on operating data from laboratory or pilot scale equipment aims to achieve conditions at production scale close to the optima determined at pilot scale (e.g. mixing time)

In larger vessels
liquid to circulate over longer distances (in proportion to vessel diameter or height) fluid velocity must be greater for constant mixing time

Scale-up issues
P Fluid velocity: v V
Increasing fluid velocity requires increased power input per unit volume of liquid Required increase in power to maintain constant tm is often technically and economically not feasible 2 For scale-up based on constant (P/V), tm Dt 3
mixing time increases with vessel size process performance may be adversely impacted

Scale-down approach to process development


If the desired conditions cannot be attained at production scale, scale-down approach may help identify best achievable performance of the process Involves pilot-scale process development under conditions realistically achievable at full-scale
e.g. investigations under reduced power input to simulate mixing time achievable at full scale.

Adapting reactor design to enhance mixing


Positioning of impeller at 1/3 vessel diameter from base in standard single impeller vessels promotes asynchronous circulation loops Use of multiple impellers in tall vessels (HL >>Dt) optimum impeller spacing is 1 to 1.5 times impeller diameter closer spacing interferes with circulation loops development and increases power consumption fluid exchange between the different mixing cells inadequate at larger spacing power absorption proportional to the No. of impellers multiple substrate feed points for more even distribution

Adapting reactor design to enhance mixing


With pseudoplastic fluids, stagnant zones can develop away from the impellers Larger impeller will improve the extent of the agitated region, although power consumption may become too large Special, low clearance impeller designs (e.g. anchor or helical ribbon) can also improve the extent of mixing as they sweep the entire liquid volume

Shear in stirred bioreactors


Average shear in stirred bioreactors: & = kN i Increasing shear rate
responsible for dispersing gas bubbles will improve oxygen mass transfer may also lead to cell damage, especially in plant and animal cell culture

Shear varies greatly with location in the vessel


high in the impeller zone low, away from the impeller where turbulence is low

Shear damage to cells in bioreactors


In ungassed systems, liquid shear in turbulent eddies is the main cause of cell damage and disruption to cell function In gassed systems, bursting of bubbles at the liquid surface appear to be the principal cause of damage to cells

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