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Received 9 June 2003; received in revised form 18 May 2004; accepted 28 July 2004
Available online 23 September 2004
Abstract
In many biological processes, increasing the rate of transport of a limiting nutrient can enhance the rate of product formation. In aerobic
fermentation systems, the rate of oxygen transfer to the cells is usually the limiting factor. A key factor that influences oxygen transfer
is bubble size distribution. The bubble sizes dictate the available interfacial area for gas–liquid mass transfer. Scale-up and design of
bioreactors must meet oxygen transfer requirements while maintaining low shear rates and a controlled flow pattern. This is the motivation
for the current work that captures multiphase hydrodynamics and simultaneously predicts the bubble size distribution.
Bubbles break up and coalesce due to interactions with turbulent eddies, giving rise to a distribution of bubble sizes. These effects
are included in the modeling approach by solving a population balance model with bubble breakage and coalescence. The population
balance model was coupled to multiphase flow equations and solved using a commercial computational fluid mechanics code FLUENT 6.
Gas holdup and volumetric mass transfer coefficients were predicted for different superficial velocities and compared to the experimental
results of Kawase and Hashimoto (1996). The modeling results showed good agreement with experiment.
䉷 2004 Elsevier Ltd. All rights reserved.
Keywords: Airlift; Bioreactor; Gas holdup; Mass transfer; Loop reactor; Bubble column reactor
The gas phase is assumed to be composed of 9 discrete bubbles of sizes i and j is expressed as (Luo, 1993)
bubble sizes and a discretized population balance equation
is solved for the bubble number density along with birth and
PC (vi , vj ) = exp −c1 L di (vi2 + vj2 )1/2
death terms due to breakup and coalescence. The equation
for the ith bubble class fraction fi is written as
[0.75(1 + 2ij )(1 + 3ij )]1/2
× , (18)
*G G fi (G /L +
)1/2 (1 + ij )3
+ ∇ · (G G ūG )fi = Si , (10)
*t where
Si = BBreakup − DBreakup + BCoalescence 12cf
= . (19)
− DCoalescence , (11) L di 2/3
The collision frequency is given as (Luo, 1993)
where fi is defined as the ratio of total volume of bubbles
of class i to the total volume of bubbles of all classes. These c (vi , vj ) = (/4)(di + dj )2 ni nj (vi2 + vj2 )1/2 . (20)
functions are expressed as
The coupling between bubble breakup and coalescence
vmax and CFD is achieved through the dynamic drag term based
Bbreakup (v; x, t) = B (v , v)n(v ; x, t) dv , (12) on the sauter mean diameter d32 .
vmax −v
Eqs. (1)–(4) and (10) were solved numerically with a com-
v/2
mercial CFD code FLUENT 6 that is based on the finite
B (v, v ) volume method.
Dbreakup (v; x, t) = n(v; x, t) dv , (13)
0 v
v/2 3. Results and discussion
Bcoalescence (v; x, t) = Pc (v − v , v).(v − v , v)
0
× n(v − v ; x, t)n(v ; x, t) dv , (14) The computational grid is shown in Fig. 1. The flow ge-
ometry was discretized into 23,000 hexahedral cells. Due to
vmax −v symmetry only one-half of the reactor geometry was mod-
Dcoalesence (v; x, t) = Pc (v, v ).(v, v ) eled. The dimensions of the riser diameter and the down-
0
comer diameter are 0.07 and 0.155 m, respectively. The vol-
× n(v; x, t)n(v ; x, t) dv . (15) ume of the reactor is 0.023 m3 . For this geometry, five CFD
runs were conducted for superficial gas velocities of 0.01,
The bubble breakup and coalescence kernels appearing in
0.02, 0.03, 0.04 and 0.05 m/s. Riser Gas holdup (
gr) was
the integrals above are described below.
calculated as the ratio of the volume increase of gas in the
Bubble breakup is analyzed in terms of bubble interac-
riser section divided by the initial liquid volume in the riser.
tions with turbulent eddies. The turbulent eddies increase the
The volumetric mass transfer coefficient was calculated as
surface energy of the bubbles through deformation. Breakup
the product of liquid-phase mass transfer coefficient (KL )
occurs if the increase in surface energy reaches a critical
and the specific surface area a.
value. A binary breakage is assumed. The kernel contains
KL is obtained from the basis of Higbie’s penetration
no adjustable parameters. The breakup rate of particles of
theory as
size into particle sizes of fBV and (1 − fBV ) is given
as (Luo, 1993) 2 √ L L 0.25
KL = √ D , (21)
1/3
L
B (v : vf BV ) 1 (1 + )2
= c4 2 where L is the water turbulent dissipation rate that is pre-
(1 − d )n d min 11/3
dicted from the CFD simulation. The interfacial area is also
12cf directly obtained from the predicted bubble size distribution
× exp − d, (16)
L 2/3 d 5/3 11/3 as
6i
where a= . (22)
di
i
2/3
cf = fBV + (1 − fBV ) 2/3
− 1. (17) Fig. 2 shows contours of air volume fraction of 0.1 for a
superficial velocity of 0.03 m/s. Fig. 3 shows contours of
Bubble coalescence is modeled by considering bubble col- air volume fraction along the symmetry plane for the same
lisions due to turbulence, buoyancy and laminar shear. The conditions. From Figs. 2 and 3 it can be seen that most of
coalescence rate is given as a product of collision frequency the air rises through the riser section and leaves the domain.
and coalescence probability. The coalescence probability of However, a small pocket of air is seen to be trapped in the
216 K.M. Dhanasekharan et al. / Chemical Engineering Science 60 (2005) 213 – 218
0.1
0.1
4. Conclusions