Constraint Handling and Flow Control in Stirred Tank Bioreactors with Magnetically Coupled Impellers

In this study, Computational Fluid Dynamics (CFD), applied to a non-Newtonian fluid, was developed to characterize gas-liquid interaction and mixing process in a 15 m³ (working volume) bioreactor. The bioreactor was equipped with four arrangements of standard Rushton, Pitch-blade and Scaba® impellers. Gas-liquid hydrodynamics was estimated based on CFD results. The chosen operating conditions were defined by the settings used for production of xanthan gum via fermentation route by Xanthomonas campestris. The mixing process was simulated by using the k-epsilon turbulence model, Multiple Reference Frame and Population Balance Model approaches. The simulation results have been compared and analyzed by isosurfaces, volume fractions, velocity graphs, torques and flow analysis calculations. Obtained results revealed that for the Pitched-Pitched-Pitched arrangement to avoid the constraint-imposed overload torque limitations impeller diameter size should be reduced by 10%. The use of Rushton-Rushton-Rushton impeller arrangement was discouraged for non-Newtonian pseudoplastic fluid mixing, whereas Pitched-Rushton-Scaba and Scaba-Rushton-Pitched impeller arrangements were both acceptable.