Hydrodynamic comparison of different geometries of square cross-section airlift bioreactor using computational fluid dynamics
Abstract
The hydrodynamics of airlift bioreactors, which offer an interesting alternative to conventional stirred-tank bioreactors, has generally been evaluated using experimental approaches, requiring time, energy, and reagents. However, computational fluid dynamics (CFD) has emerged as an important and valuable tool for the analysis and design of these devices, saving time and experimental effort, while providing a large amount of information. In this study, four geometries of a square cross-section 10-L split airlift bioreactor operating with distilled water were simulated using CFD, and the hydrodynamics variables gas hold-up and liquid velocity were evaluated. CFD satisfactorily predicted the hydrodynamic parameters, when compared to experimental data, allowing adequate prediction of the shear rate distribution in airlift bioreactors. The results indicated that different shear rate distributions were obtained by geometric modifications in the bioreactor, showing that its design should be considered to satisfy different specific bioprocess requirements.
Funding source: Coordenação de Aperfeiçoamento de Pessoal de Nível Superior
Award Identifier / Grant number: Finance Code 001
Funding source: Human Resources Program of the Brazilian National Agency of Petroleum, Natural Gas, and Biofuels
Award Identifier / Grant number: PRH/ANP-39
Funding source: Fundação de Amparo à Pesquisa do Estado de São Paulo
Award Identifier / Grant number: 2011/23807-1
Award Identifier / Grant number: 2012/17756-8
Award Identifier / Grant number: 2020/08699-7
Funding source: Conselho Nacional de Desenvolvimento Científico e Tecnológico
Award Identifier / Grant number: 309728/2021-5
-
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
-
Research funding: The authors are grateful for the financial support provided by the Human Resources Program of the Brazilian National Agency of Petroleum, Natural Gas, and Biofuels (PRH/ANP-39), Coordenaçã çoamento de Pessoal de Nível Superior – Brasil (CAPES, Finance Code 001), the National Council for Scientific and Technological Development (CNPq, grant 309728/2021-5), and the São Paulo State Research Foundation (FAPESP, grants 2011/23807-1, 2012/17756-8, and 2020/08699-7).
-
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.
References
Al-Masry, W. A. 1999. “Effect of Scale-Up on Average Shear Rates for Aerated Non-Newtonian Liquids in External Loop Airlift Reactors.” Biotechnology and Bioengineering 62 (4): 494–8. https://doi.org/10.1002/(sici)1097-0290(19990220)62:4<494::aid-bit14>3.0.co;2-6.10.1002/(SICI)1097-0290(19990220)62:4<494::AID-BIT14>3.0.CO;2-6Search in Google Scholar
Al-Masry, W. A., and M. Chetty. 1996. “On the Estimation of Effective Shear Rate in External Loop Airlift Reactors: Non-Newtonian Fluids.” Resources, Conservation and Recycling 18 (1–4): 11–24. https://doi.org/10.1016/s0921-3449(96)01164-0.Search in Google Scholar
Ali, R. M., C. Jamel, B. Ghazi, and A. Line. 2011. “Gas Dispersion in Air-Lift Reactors: Contribution of the Turbulent Part of the Added Mass Force.” AIChE Journal 57 (12): 3315–30. https://doi.org/10.1002/aic.12539.Search in Google Scholar
Anastasiou, A. D., A. D. Passos, and A. A. Mouza. 2013. “Bubble Columns with Fine Pore Sparger and Non-Newtonian Liquid Phase: Prediction of Gas Holdup.” Chemical Engineering Science 98: 331–8. https://doi.org/10.1016/j.ces.2013.05.006.Search in Google Scholar
Bando, Y., K. Fujimori, H. Terazawa, K. Yasuda, and M. Nakamura. 2000. “Effects of Equipment Dimensions on Circulation Flow Rates of Liquid and Gas in Bubble Column with Draft Tube.” Journal of Chemical Engineering of Japan 33 (3): 379–85. https://doi.org/10.1252/jcej.33.379.Search in Google Scholar
Bannari, R., A. Bannari, B. Selma, and P. Proulx. 2011. “Mass Transfer and Shear in an Airlift Bioreactor: Using a Mathematical Model to Improve Reactor Design and Performance.” Chemical Engineering Science 66 (10): 2057–67. https://doi.org/10.1016/j.ces.2011.01.038.Search in Google Scholar
Celik, I. B., U. Ghia, P. J. Roache, and C. J. Freitas. 2008. “Procedure for Estimation and Reporting of Uncertainty Due to Discretization in CFD Applications.” Journal of Fluids Engineering-Transactions of the Asme 130 (7): 1–4.10.1115/1.2960953Search in Google Scholar
Cerri, M. O., L. Futiwaki, C. D. F. Jesus, A. J. G. Cruz, and A. C. Badino. 2008. “Average Shear Rate for Non-Newtonian Fluids in a Concentric-Tube Airlift Bioreactor.” Biochemical Engineering Journal 39 (1): 51–7. https://doi.org/10.1016/j.bej.2007.08.009.Search in Google Scholar
Cerri, M. O., L. M. Policarpo, and A. C. Badino. 2010. “Gas Hold-Up and Mass Transfer in Three Geometrically Similar Internal Loop Airlift Reactors Using Newtonian Fluids.” International Journal of Chemical Reactor Engineering 8: 1–24, https://doi.org/10.2202/1542-6580.1987.Search in Google Scholar
Chisti, Y. 1989. Airlift Bioreactors. London: Elsevier Science Publishers Ltd.Search in Google Scholar
Contreras, A., F. Garcia, E. Molina, and J. C. Merchuk. 1999. “Influence of Sparger on Energy Dissipation, Shear Rate, and Mass Transfer to Sea Water in a Concentric-Tube Airlift Bioreactor.” Enzyme and Microbial Technology 25 (10): 820–30. https://doi.org/10.1016/s0141-0229(99)00119-2.Search in Google Scholar
Esperança, M. N., R. Bettega, and A. C. Badino. 2017. “Effect of Geometric Design on Performance of Square Cross-Section Concentric-Duct and Split Airlift Bioreactors.” Canadian Journal of Chemical Engineering 95 (12): 2324–32. https://doi.org/10.1002/cjce.23024.Search in Google Scholar
Esperança, M. N., C. E. Mendes, G. Y. Rodriguez, M. O. Cerri, R. Bettega, and A. C. Badino. 2019. “Average Shear Rate in Airlift Bioreactors: Searching for the True Value.” Bioprocess and Biosystems Engineering 42 (6): 995–1008. https://doi.org/10.1007/s00449-019-02100-1.Search in Google Scholar PubMed
Esperança, M. N., C. E. Mendes, G. Y. Rodriguez, M. O. Cerri, R. Bettega, and A. C. Badino. 2020. “Sparger Design as Key Parameter to Define Shear Conditions in Pneumatic Bioreactors.” Biochemical Engineering Journal 157: 1–12, https://doi.org/10.1016/j.bej.2020.107529.Search in Google Scholar
Garcia, S., E. Paternina, O. R. Pupo, A. Bula, and L. Di Mare. 2014. “CFD Simulation of Multiphase Flow in an Airlift Column Photobioreactor.” Global Nest Journal 16 (6): 1121–34.10.30955/gnj.001478Search in Google Scholar
Ghasemi, H., and S. H. Hosseini. 2012. “Investigation of Hydrodynamics and Transition Regime in an Internal Loop Airlift Reactor Using CFD.” Brazilian Journal of Chemical Engineering 29 (4): 821–33. https://doi.org/10.1590/s0104-66322012000400013.Search in Google Scholar
Gouveia, E. R., C. O. Hokka, and A. C. Badino. 2003. “The Effects of Geometry and Operational Conditions on Gas Holdup, Liquid Circulation and Mass Transfer in an Airlift Reactor.” Brazilian Journal of Chemical Engineering 20 (4): 363–74. https://doi.org/10.1590/s0104-66322003000400004.Search in Google Scholar
Grace, J. R., T. Wairegi, and T. H. Nguyen. 1976. “Shapes and Velocities of Single Drops and Bubbles Moving Freely through Immiscible Liquids.” Transactions of the Institution of Chemical Engineers 54 (3): 167–73.Search in Google Scholar
Grima, E. M., Y. Chisti, and M. MooYoung. 1997. “Characterization of Shear Rates in Airlift Bioreactors for Animal Cell Culture.” Journal of Biotechnology 54 (3): 195–210. https://doi.org/10.1016/s0168-1656(97)00043-6.Search in Google Scholar
Kelly, W. J. 2008. “Using Computational Fluid Dynamics to Characterize and Improve Bioreactor Performance.” Biotechnology and Applied Biochemistry 49 (4): 225–38, https://doi.org/10.1042/ba20070177.Search in Google Scholar PubMed
Kilonzo, P. M., A. Margaritis, M. A. Bergougnou, J. T. Yu, and Y. Qin. 2006. “Influence of the Baffle Clearance Design on Hydrodynamics of a Two Riser Rectangular Airlift Reactor with Inverse Internal Loop and Expanded Gas-Liquid Separator.” Chemical Engineering Journal 121 (1): 17–26. https://doi.org/10.1016/j.cej.2006.05.003.Search in Google Scholar
Kilonzo, P. M., A. Margaritis, and M. A. Bergougnou. 2010. “Hydrodynamic Characteristics in an Inverse Internal-Loop Airlift-Driven Fibrous-Bed Bioreactor.” Chemical Engineering Science 65 (2): 692–707. https://doi.org/10.1016/j.ces.2009.09.023.Search in Google Scholar
Lestinsky, P., M. Vecer, P. Vayrynen, and K. Wichterle. 2015. “The Effect of the Draft Tube Geometry on Mixing in a Reactor with an Internal Circulation Loop – A CFD Simulation.” Chemical Engineering and Processing 94: 29–34. https://doi.org/10.1016/j.cep.2015.03.009.Search in Google Scholar
Luo, H. P., and M. H. Al-Dahhan. 2008. “Macro-mixing in a Draft-Tube Airlift Bioreactor.” Chemical Engineering Science 63 (6): 1572–85. https://doi.org/10.1016/j.ces.2007.11.027.Search in Google Scholar
Mavaddat, P., S. M. Mousavi, E. Amini, H. Azargoshasb, and S. A. Shojaosadati. 2014. “Modeling and CFD-PBE Simulation of an Airlift Bioreactor for PHB Production.” Asia-Pacific Journal of Chemical Engineering 9 (4): 562–73. https://doi.org/10.1002/apj.1785.Search in Google Scholar
Mehrnia, M. R., B. Bonakdarpour, J. Towfighi, and M. M. Akamejad. 2004. “Design and Operational Aspects of Airlift Bioreactors for Petroleum Biodesulfurization.” Environmental Progress 23 (3): 206–14. https://doi.org/10.1002/ep.10024.Search in Google Scholar
Mendes, C. E. 2016. Evaluation of Hydrodynamic, Oxygen Transfer and Shear Conditions in Different Models and Scales of Pneumatic Reactors. São Carlos: Federal University of São Carlos.Search in Google Scholar
Mendes, C. E., and A. C. Badino. 2016. “Hydrodynamics of Newtonian and Non-Newtonian Liquids in Internal-Loop Airlift Reactors.” Biochemical Engineering Journal 109: 137–52. https://doi.org/10.1016/j.bej.2016.01.007.Search in Google Scholar
Merchuk, J. C., and S. Benzvi. 1992. “A Novel Approach to the Correlation of Mass Transfer Rates in Bubble-Columns with Non-Newtonian Liquids.” Chemical Engineering Science 47 (13–14): 3517–23. https://doi.org/10.1016/0009-2509(92)85065-j.Search in Google Scholar
Merchuk, J. C., and I. Berzin. 1995. “Distribution of Energy Dissipation in Airlift Reactors.” Chemical Engineering Science 50 (14): 2225–33. https://doi.org/10.1016/0009-2509(95)00027-3.Search in Google Scholar
Merchuk, J. C., N. Ladwa, A. Cameron, M. Bulmer, I. Berzin, and A. M. Pickett. 1996. “Liquid Flow and Mixing in Concentric Tube Air-Lift Reactors.” Journal of Chemical Technology and Biotechnology 66 (2): 174–82. https://doi.org/10.1002/(sici)1097-4660(199606)66:2<174::aid-jctb481>3.0.co;2-3.10.1002/(SICI)1097-4660(199606)66:2<174::AID-JCTB481>3.0.CO;2-3Search in Google Scholar
Moradi, S., Z. Rajabi, M. Mohammadi, M. Salimi, S. S. Homami, M. K. Seydei, and S. Shirazian. 2013. “3 Dimensional Hydrodynamic Analysis of Concentric Draft Tube Airlift Reactors with Different Tube Diameters.” Mathematical and Computer Modelling 57 (5–6): 1184–9. https://doi.org/10.1016/j.mcm.2012.10.021.Search in Google Scholar
Mostoufi, N., M. R. Mehrnia, and M. Vali. 2014. “Hydrodynamics of an Airlift Bioreactor Treating Petroleum-Based Liquids: Experiment and CFDM.” Energy Sources, Part A: Recovery, Utilization, and Environmental Effects 36 (12): 1296–304. https://doi.org/10.1080/15567036.2011.551919.Search in Google Scholar
Nadal-Rey, G., D. D. McClure, J. M. Kavanagh, B. Cassells, S. Cornelissen, D. F. Fletcher, and K. V. Gernaey. 2022. “Computational Fluid Dynamics Modelling of Hydrodynamics, Mixing and Oxygen Transfer in Industrial Bioreactors with Newtonian Broths.” Biochemical Engineering Journal 177: 1–18, https://doi.org/10.1016/j.bej.2021.108265.Search in Google Scholar
Nishikawa, M., H. Kato, and K. Hashimoto. 1977. “Heat-transfer in Aerated Tower Filled with Non-Newtonian Liquid.” Industrial and Engineering Chemistry Process Design and Development 16 (1): 133–7. https://doi.org/10.1021/i260061a607.Search in Google Scholar
Ouyoung, P. K., Y. Chisti, and M. Moo-Young. 1989. “Heat-transfer in Airlift Reactors.” Chemical Engineering Research and Design 67 (5): 451–6.Search in Google Scholar
Pawar, S. B. 2017. “CFD Analysis of Flow Regimes in Airlift Reactor Using Eulerian-Lagrangian Approach.” Canadian Journal of Chemical Engineering 95 (3): 420–31. https://doi.org/10.1002/cjce.22696.Search in Google Scholar
Pawar, S. B. 2018. “Computational Fluid Dynamics (CFD) Analysis of Airlift Bioreactor: Effect of Draft Tube Configurations on Hydrodynamics, Cell Suspension, and Shear Rate.” Bioprocess and Biosystems Engineering 41 (1): 31–45. https://doi.org/10.1007/s00449-017-1841-8.Search in Google Scholar PubMed
Rodriguez, G. Y., M. Valverde-Ramirez, C. E. Mendes, R. Bettega, and A. C. Badino. 2015. “Global Performance Parameters for Different Pneumatic Bioreactors Operating with Water and Glycerol Solution: Experimental Data and CFD Simulation.” Bioprocess and Biosystems Engineering 38 (11): 2063–75. https://doi.org/10.1007/s00449-015-1446-z.Search in Google Scholar PubMed
Ruen-Ngam, D., P. Wongsuchoto, A. Limpanuphap, T. Charinpanitkul, and P. Pavasant. 2008. “Influence of Salinity on Bubble Size Distribution and Gas-Liquid Mass Transfer in Airlift Contactors.” Chemical Engineering Journal 141 (1–3): 222–32. https://doi.org/10.1016/j.cej.2007.12.024.Search in Google Scholar
Schumpe, A., and W. D. Deckwer. 1987. “Viscous Media in Tower Bioreactors - Hydrodynamic Characteristics and Mass-Transfer Properties.” Bioprocess Engineering 2 (2): 79–94. https://doi.org/10.1007/bf00369528.Search in Google Scholar
Shi, L. K., J. P. Riba, and H. Angelino. 1990. “Estimation of Effective Shear Rate for Aerated Non-Newtonian Liquids in Airlift Bioreactor.” Chemical Engineering Communications 89: 25–35. https://doi.org/10.1080/00986449008940556.Search in Google Scholar
Simcik, M., A. Mota, M. C. Ruzicka, A. Vicente, and J. Teixeira. 2011. “CFD Simulation and Experimental Measurement of Gas Holdup and Liquid Interstitial Velocity in Internal Loop Airlift Reactor.” Chemical Engineering Science 66 (14): 3268–79. https://doi.org/10.1016/j.ces.2011.01.059.Search in Google Scholar
Thomasi, S. S., M. O. Cerri, and A. C. Badino. 2010. “Average Shear Rate in Three Pneumatic Bioreactors.” Bioprocess and Biosystems Engineering 33 (8): 979–88. https://doi.org/10.1007/s00449-010-0422-x.Search in Google Scholar PubMed
Vasconcelos, J. M. T., J. M. L. Rodrigues, S. C. P. Orvalho, S. S. Alves, R. L. Mendes, and A. Reis. 2003. “Effect of Contaminants on Mass Transfer Coefficients in Bubble Column and Airlift Contactors.” Chemical Engineering Science 58 (8): 1431–40. https://doi.org/10.1016/s0009-2509(02)00675-9.Search in Google Scholar
Xu, T., X. Jiang, N. Yang, and J. Zhu. 2015. “CFD Simulation of Internal-Loop Airlift Reactor Using EMMS Drag Model.” Particuology 19: 124–32. https://doi.org/10.1016/j.partic.2014.04.016.Search in Google Scholar
Zhang, N., T. Wang, Z. Deng, and J. Wang. 2010. “Self-Oscillations in an Airlift Reactor.” Chemical Engineering Journal 160 (1): 277–83. https://doi.org/10.1016/j.cej.2010.03.005.Search in Google Scholar
Zhang, T., C. Wei, C. Feng, and J. Zhu. 2012. “A Novel Airlift Reactor Enhanced by Funnel Internals and Hydrodynamics Prediction by the CFD Method.” Bioresource Technology 104: 600–7. https://doi.org/10.1016/j.biortech.2011.11.008.Search in Google Scholar PubMed
Zhang, W., Y. Yong, G. Zhang, C. Yang, and Z. Mao. 2014. “Mixing Characteristics and Bubble Behavior in an Airlift Internal Loop Reactor with Low Aspect Ratio.” Chinese Journal of Chemical Engineering 22 (6): 611–21. https://doi.org/10.1016/s1004-9541(14)60089-6.Search in Google Scholar
Supplementary Material
This article contains supplementary material (https://doi.org/10.1515/ijcre-2023-0010).
© 2023 Walter de Gruyter GmbH, Berlin/Boston
Articles in the same Issue
- Frontmatter
- Articles
- Methylene blue removal from aqueous solution using modified Met-SWCNT-Ag nanoparticles: optimization using RSM-CCD
- Leaching behavior of germanium presented in different phases from zinc oxide dust under atmospheric acid leaching conditions
- TiO2 P25 and Kronos vlp 7000 materials activated by simulated solar light for atrazine degradation
- Numerical investigations on hydrothermal flame characteristics of water-cooled hydrothermal burner
- Moving bed biofilm reactor combined with an activated carbon filter for biological nitrate removal
- Preparation of bimodal mesoporous CoCe composite oxide for ethanol complete oxidation in air
- Hydrocracking of hydrotreated light cycle oil for optimizing BTEX production: a simple kinetic model
- Hydrodynamic comparison of different geometries of square cross-section airlift bioreactor using computational fluid dynamics
- Influence of different influence parameters on mixing characteristics of silicon particles in cassette
Articles in the same Issue
- Frontmatter
- Articles
- Methylene blue removal from aqueous solution using modified Met-SWCNT-Ag nanoparticles: optimization using RSM-CCD
- Leaching behavior of germanium presented in different phases from zinc oxide dust under atmospheric acid leaching conditions
- TiO2 P25 and Kronos vlp 7000 materials activated by simulated solar light for atrazine degradation
- Numerical investigations on hydrothermal flame characteristics of water-cooled hydrothermal burner
- Moving bed biofilm reactor combined with an activated carbon filter for biological nitrate removal
- Preparation of bimodal mesoporous CoCe composite oxide for ethanol complete oxidation in air
- Hydrocracking of hydrotreated light cycle oil for optimizing BTEX production: a simple kinetic model
- Hydrodynamic comparison of different geometries of square cross-section airlift bioreactor using computational fluid dynamics
- Influence of different influence parameters on mixing characteristics of silicon particles in cassette