CHE 514A: BIOCHEMICAL ENGINEERING

Determination of Oxygen-Absorption Rate

Our objective in fermenter design is to maximize the oxygen transfer rate with the minimum power
consumption necessary to agitate the fluid, and also minimum air flow rate. The main parameters of interest in design
are the mass-transfer coefficient and interfacial area.

Where:
qA/V = oxygen absorption rate
KLa = overall volumetric mass transfer coefficient
KLa = individual volumetric mass transfer coefficient

Due to the ever changing rheology of the medium, the absorption of oxygen in the medium can be measured by
simulation by using synthetic systems which approximates fermentation conditions. (Read in the book the various
methods used for approximation. Kindly study ex. 9.5 on your own. Since that is easy.)

Sample problem on Dynamic method:

A 20 L stirred fermenter containing a Bacillus thuringiensis culture at 30°C is used for production of microbial insecticide,
kLa is determined using the dynamic method. Air flow is shut off for a few minutes and the dissolved-oxygen level drops;
the air supply is then re-connected. When steady state is established, the dissolved-oxygen tension is 78% air saturation.
The following results are obtained.
Time (s) 5 15
Oxygen Tension (% air saturation) 50 66
(a) Estimate kLa.
(b) An error is made determining the steady-state oxygen level which, instead of 78%, is taken as 70%. What is the
percentage error in kLa resulting from this 10% error in CL*?

SOLUTION:
a. The dissolved oxygen tension stated in the problem is CL*. So substituting,
𝐶𝐿∗ − 𝐶𝐿(𝑡1)
ln [ ∗ ]
𝐶𝐿 − 𝐶𝐿(𝑡2)
𝑘𝐿 𝑎 =
𝑡2 − 𝑡1
78 − 50
ln [ ]
𝑘𝐿 𝑎 = 78 − 66
15 − 5

𝑘𝐿 𝑎 = 0.085/s

b. CL* becomes 70% instead of 78%.

70 − 50
ln [ ]
𝑘𝐿 𝑎 = 70 − 66
15 − 5
𝑘𝐿 𝑎 = 0.16/𝑠

0.16 − 0.085
% 𝑒𝑟𝑟𝑜𝑟 = 𝑥100
0.085

% 𝑒𝑟𝑟𝑜𝑟 = 88.2353% 10
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The value of kLa for the oxygen absorption rate is important. Various correlations were created in order to
estimate its value depending on various conditions during fermentation (refer to book).

SCALE-UP: SIMILITUDE

One of the basics that needs to be done before creating process equipment is to create small-scale models.
Aside from this, a prototype must first be created from the model in order to check the success of the design. This is also
to ensure that any problems encountered in the process can be taken care of immediately. The fundamental
requirement for scale-up is that the model and prototype should be similar to each other.

There are two conditions that must be satisfied in order to ensure similarity between the model and prototype.
1. Geometric similarity of the physical boundaries:
The model and prototype should be the same shape, both should be rectangular or cylindrical and
others. The linear dimensions of the model must be related to the corresponding dimensions of the prototype
by a constant scale factor. For example, the height of the fermenter prototype is twice the height of the model
fermenter. Or, the impeller diameter of the model is 1/3 of the impeller diameter of the prototype.

2. Dynamic similarity of the flow fields:

The ratio of flow velocities of corresponding fluid particles is the same in model and prototype as well as
the ratio of all forces acting on corresponding fluid particles. When dynamic similarity of two flow fields with
geometrically similar boundaries is achieved, the flow fields exhibit geometrically similar flow patterns. If the
medium exhibits turbulent flow in the model, medium in the prototype should also exhibit turbulent flow.

The various forces acting on the fluid or medium are viscosity force FV, drag force on impeller FD, and gravity
force FG. For viscosity force FV, it can be assumed that the average velocity gradient is proportional to agitation speed N
and the area A is to DI2 , which results
𝐹𝑉 ∝ 𝜇𝑁𝐷𝐼2

The drag force FD can be characterized in an agitating system as

𝑃𝑚𝑜
𝐹𝐷 ∝
𝐷𝐼 𝑁
Since gravity force FG is equal to mass m times gravity constant g,

𝐹𝐺 ∝ 𝜌𝐷𝐼3 𝑔

The summation of all forces is equal to the inertial force F I as,

∑ 𝐹 = 𝐹𝑉 + 𝐹𝐷 + 𝐹𝐺

Then the dynamic similarity between a model (m), and a prototype (p) is achieved if

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Or in dimensionless forms:

Simplifying the forces in terms of dimensionless groups (refer to book),

Dynamic similarity is achieved when the values of the non-dimensional parameters are the same as geometrically similar
locations.

Therefore, using dimensionless parameters for the correlation of data has advantages not only for the consistency of
units, but also for the scale-up purposes.

However, it is difficult, if not impossible, to satisfy dynamic similarity when more than one dimensionless group is
involved in a system, which creates the needs for scale-up criteria.

Ex. 9.7:
The power consumption by an agitator in an unbaffled vessel can be expressed as:
𝑃𝑚𝑜 𝜌𝑁𝐷𝐼2 𝑁 2 𝐷𝐼
= 𝑓 ( , )
𝜌𝑁 3 𝐷𝐼5 𝜇 𝑔
Can you determine the power consumption and impeller speed of a 1,000-gallon fermenter based on the findings of the
optimum condition from a geometrically similar one-gallon vessel? If you cannot, can you scale up by using a different
fluid system?
GIVEN:
𝑃𝑚𝑜 𝜌𝑁𝐷𝐼2 𝑁 2 𝐷𝐼
= 𝑓 ( , )
𝜌𝑁 3 𝐷𝐼5 𝜇 𝑔
REQUIRED: Pmo and N for V=1000 gallon (prototype) based on V=1 gallon (model) if not possible diff. fluid?
SOLUTION:
In order to solve for the properties of the prototype using the model, we need to establish a scale-up ratio using
geometric similarity. Taking the ratio of the volume,
𝑉𝑃 1000
=
𝑉𝑀 1
Reviewing the dimensionless numbers established earlier, the dimension we primarily need is the impeller diameter D I.
So from the volume,
𝜋
𝑉 = 𝐷𝑇2 𝐻
4
Assume DT = H.
𝜋
( 𝐷𝑇3 ) 1000
4 𝑃
𝜋 3 =
( 𝐷𝑇 ) 1
4 𝑀

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The π/4 will cancel out since it is constant. Then take the cube root of each side. So,
𝐷𝑇,𝑃
= 10
𝐷𝑇,𝑀

In order to achieve geometric similarity during a scale-up, the ratio for the dimensions should be equal. Therefore,
𝐷𝐼 𝐷𝐼
( ) =( )
𝐷𝑇 𝑃 𝐷𝑇 𝑀

This means that,

𝐷𝐼,𝑃
= 10
𝐷𝐼,𝑀

The scale-up ratio is now established in terms of DI which is present in the dimensionless numbers mentioned in the
concept part. In order to solve for Pmo, we will use the Np since Pmo is present there. To achieve dynamic similarity,
𝑁𝑝𝑃 = 𝑁𝑝𝑀
Substituting the formula of Np.

𝑃𝑚𝑜 𝑃𝑚𝑜
( 5) = ( )
3
𝜌𝑁 𝐷𝐼 𝑃 𝜌𝑁 3 𝐷𝐼5 𝑀

Isolating the Pmo of the prototype on one side of the equation.

𝑃𝑚𝑜
𝑃𝑚𝑜𝑃 = (𝜌𝑁 3 𝐷𝐼5 )𝑃 ( )
𝜌𝑁 3 𝐷𝐼5 𝑀

Since we have the same fluid in the prototype and model, the density would cancel out. Rearranging,
(𝑁 3 𝐷𝐼5 )𝑃
𝑃𝑚𝑜𝑃 = 𝑃𝑚𝑜𝑀 3 5
(𝑁 𝐷𝐼 )𝑀

Substituting the scale-up ratio,

(𝑁 3 )𝑃
𝑃𝑚𝑜𝑃 = 𝑃𝑚𝑜𝑀 (10)5
(𝑁 3 )𝑀

So to be able to solve for the Pmo of the prototype, we need the Pmo of the model and the ratio of the impeller speed.
Using another dimensionless number, this time Re because N is present here. Again, for dynamic similarity,
𝑅𝑒𝑖𝑃 = 𝑅𝑒𝑖𝑀
𝜌𝑁𝐷𝐼2 𝜌𝑁𝐷𝐼2
( ) =( )
𝜇 𝑃
𝜇 𝑀
Since both the prototype and model have the same fluid,
(𝑁𝐷𝐼2 )𝑃 = (𝑁𝐷𝐼2 )𝑀
Substituting the scale-up ratio,
2
𝐷𝐼,𝑀
𝑁,𝑃 = 𝑁,𝑀 2
𝐷𝐼,𝑃
1 2
𝑁,𝑃 = 𝑁,𝑀 ( )
10
𝑁,𝑃 = 𝑁,𝑀 (0.01)

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N is also present in the Fr. So,

𝐹𝑟𝑃 = 𝐹𝑟𝑀
𝑁 2 𝐷𝐼 𝑁 2 𝐷𝐼
( ) =( )
𝑔 𝑃 𝑔 𝑀
Simplifying,
𝐷𝐼,𝑀
𝑁,𝑃 = 𝑁,𝑀 √
𝐷𝐼,𝑃

1
𝑁,𝑃 = 𝑁,𝑀 √
10
𝑁,𝑃 = 𝑁,𝑀 (0.3162)

Comparing the relationship derived by Re and Fr for N, the ratio is not equal. Re derived that the factor needed is 0.01
while for Fr it is 0.3162. This shows that it is not possible to equate all dimensionless numbers to achieve dynamic
similarity.

If we are to change the fluid for model and prototype, the relationship derived by Fr will not change since it is not
affected by the fluid changing. So, resolving the Re.
𝑅𝑒𝑖𝑃 = 𝑅𝑒𝑖𝑀
𝜌𝑁𝐷𝐼2 𝜌𝑁𝐷𝐼2
( ) =( )
𝜇 𝑃
𝜇 𝑀

𝜌 𝜌 (𝑁𝐷𝐼2 )𝑀
( ) =( )
𝜇 𝑃 𝜇 𝑀 (𝑁𝐷𝐼2 )𝑃

Substituting the scale-up ratio and the relationship derived by Fr,

𝜌 𝜌 𝑁,𝑀 1 2
( ) =( ) ( )( )
𝜇 𝑃 𝜇 𝑀 𝑁,𝑀 (0.3162) 10
𝜌 𝜌
( ) = ( ) (0.0316)
𝜇 𝑃 𝜇 𝑀

If let’s say that the fluid used in the model is water then the kinematic viscosity of the fluid in the prototype should be
1/31.6 of the kinematic viscosity of water. It is impossible to find a fluid with a kinematic viscosity that small. So, as a
conclusion if all three dimensionless numbers are important, it is impossible to achieve dynamic similarity.

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The previous example problem illustrates the difficulties involved in the scale-up of the findings of small-scale
results. Therefore, we need to reduce the number of dimensionless parameters involved to as few as possible, and we
also need to determine which is the most important parameter, so that we may set this parameter constant. However,
even though only one dimensionless parameter may be involved, we may need to define the scale-up criteria.

There is no one scale-up rule that applies to many different kinds of mixing operations. Theoretically we can
scale up based on geometrical and dynamic similarities, but it has been shown that it is possible for only a few limited
cases. However, some principles for the scale-up are as follows (Oldshue, 1985):

1. It is important to identify which properties are important for the optimum operation of a mixing system.
2. The major differences between a big tank and a small tank are that the big tank has a longer blend time, a higher
maximum impeller shear rate, and a lower average impeller shear rate.
3. For homogeneous chemical reactions, the power per volume can be used as a scale-up criterion.
4. For the scale-up of the gas-liquid contactor, the volumetric mass-transfer coefficient kLa can be used as a scale-
up criterion.
5. Typical impeller-to-tank diameter ratio DI/DT for fermenters is 0.33 to 0.44.

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