化工学报 ›› 2022, Vol. 73 ›› Issue (6): 2698-2707.doi: 10.11949/0438-1157.20220089

• 催化、动力学与反应器 • 上一篇    下一篇

基于介尺度PBM模型的生物反应器放大模拟及实验研究

万景1(),张霖2,樊亚超2,刘勰民1,骆培成3,张锋1(),张志炳1   

  1. 1.南京大学化学化工学院,江苏 南京 210023
    2.中国石化大连石油化工研究院,辽宁 大连 116045
    3.东南大学化学化工学院,江苏 南京 211189
  • 收稿日期:2022-01-17 修回日期:2022-03-31 出版日期:2022-06-05 发布日期:2022-06-30
  • 通讯作者: 张锋 E-mail:1146866379@qq.com;zf@nju.edu.cn
  • 作者简介:万景(1998—),男,硕士研究生,1146866379@qq.com
  • 基金资助:
    国家自然科学基金项目(21776122);中国石油化工股份有限公司大连石油化工研究院合作项目(418012-3)

Bioreactor scale-up simulation and experimental study based on mesoscale PBM model

Jing WAN1(),Lin ZHANG2,Yachao FAN2,Xiemin LIU1,Peicheng LUO3,Feng ZHANG1(),Zhibing ZHANG1   

  1. 1.School of Chemistry and Chemical Engineering, Nanjing University, Nanjing 210023, Jiangsu, China
    2.Dalian Research Institute of Petroleum and Petrochemicals, SINOPEC, Dalian 116045, Liaoning, China
    3.School of Chemistry and Chemical Engineering, Southeast University, Nanjing 211189, Jiangsu, China
  • Received:2022-01-17 Revised:2022-03-31 Published:2022-06-05 Online:2022-06-30
  • Contact: Feng ZHANG E-mail:1146866379@qq.com;zf@nju.edu.cn

摘要:

对于通气搅拌式工业生物反应器的放大设计而言,精确预测气泡尺寸和体积传质系数非常重要,因此需要建立合适的气泡聚并和破碎模型,以保证反应器的高效操作。以5 L通气搅拌式生物反应器为对象,以气泡尺寸和体积传质系数的实验数据为基准,模拟并考察了两种聚并模型和四种破碎模型对生物反应器内流体流动行为以及传质能力的影响。结果表明,基于介尺度理论的修正聚并模型与考虑黏流剪切的破碎模型组合,所得模拟结果与实验数据吻合最好,这为大型生物反应器的桨型优化提供了模型基础。因为工业化生物发酵通常是在大型生物反应器中进行,搅拌桨型对生物反应器效能至关重要,故本研究在选定最优气泡聚并破碎模型的基础上,通过叶轮末端剪切力相等的放大原则将5 L通气搅拌式工业生物反应器放大到400 m3,同时考察了六斜叶圆盘搅拌桨、非对称式抛物线搅拌桨、布鲁马金式搅拌桨以及六直叶圆盘搅拌桨等桨型组合对气泡破碎能力和气体分散效果的影响,并通过综合对比气含率、体积传质系数等参数,得到400 m3通气搅拌式生物反应器的最优桨型组合。

关键词: 生物反应器, 计算流体力学, 放大设计, 聚并模型, 破碎模型, 优化设计

Abstract:

Accurate prediction of bubble size and volumetric mass transfer coefficient is very important for the scale-up design of aerated-stirred industrial bioreactors, and thus it is necessary to establish a suitable bubble coalescence and breakup model to ensure the efficient operation of the reactor. In this work, taking a 5 L aerated agitated bioreactor as a sample, and based on experimental data of bubble size and volumetric mass transfer coefficient, the effects of two coalescence models and five breakup models on the simulated flow behavior and mass transfer capacity were investigated. The results show that the combined simulation results of the modified coalescence model proposed based on the mesoscale and the breakup model considering viscous shear are in the best agreement with the experimental data, this provides a model basis for the paddle type optimization of large bioreactors. Because industrial bio-fermentation is usually carried out in large bioreactors, where the stirring paddle type is crucial to the bioreactor efficiency, this paper enlarges the 5 L aerated stirred industrial bioreactor to 400 m3 by the principle of equal terminal shearing force of the impeller on the basis of the optimal bubble aggregation and fragmentation model, and the influence of the combination of six-vertical-leaf disk turbine impellers, asymmetric parabolic impellers, Blumarkin impellers and six straight-blade disk turbine impellers on the bubble breaking capacity and gas dispersion effect were discussed. The optimal model combination is further used to optimize the stirring paddle type of a 400 m3 large-scale industrial bioreactor, meanwhile, the optimal combination of 400 m3 aeration-stirred bioreactor is obtained by comprehensively comparing multiple parameters such as gas holdup and volumetric mass transfer coefficient.

Key words: bioreactors, computational fluid dynamics, scale-up design, coalescence model, breakup model, optimal design

中图分类号: 

  • TQ 021.4

图1

生物反应器实验装置"

表1

本文研究的聚并模型详细信息"

聚并模型简称聚并模型
C1Luo
C2Mc-Luo

表2

本文研究的破碎模型详细信息"

破碎模型简称碰撞频率
B1ω1
B2ω2+ω3
B3ω2+ω4
B4ω5

图2

网格数量对模拟kLa和d32的影响"

图3

0、200、300、400 r/min的气泡图(a); 不同模型不同转速下的平均直径(b)"

图4

最优模型组合下不同转速的气泡直径分布"

图5

DO值随时间的变化曲线(a)和拟合曲线(b),不同模型组合在不同转速下的kLa(c)"

表3

不同实验次数下kLa随转速的变化情况"

试验次数传质系数kLa
200 r/min300 r/min400 r/min
第一次0.01550.02420.0384
第二次0.01530.02370.0378
第三次0.01580.02440.0387

图6

最优模型组合下不同转速的体积传质系数分布"

图7

400 m3生物反应器桨型组合"

图8

400 m3生物反应器不同桨型气含率分布"

图9

400 m3生物反应器kLa分布"

8 Yang N, Xiao Q. A mesoscale approach for population balance modeling of bubble size distribution in bubble column reactors[J]. Chemical Engineering Science, 2017, 170: 241-250.
9 肖颀, 杨宁. 基于EMMS模型的搅拌釜内气液两相流数值模拟[J]. 化工学报, 2016, 67(7): 2732-2739.
Xiao Q, Yang N. Numerical simulation of gas-liquid flow in stirred tanks based on EMMS model[J]. CIESC Journal, 2016, 67(7): 2732-2739.
10 Luo H A, Svendsen H F. Theoretical model for drop and bubble breakup in turbulent dispersions[J]. AIChE Journal, 1996, 42(5): 1225-1233.
11 Han L C, Luo H A, Liu Y J. A theoretical model for droplet breakup in turbulent dispersions[J]. Chemical Engineering Science, 2011, 66(4): 766-776.
12 Han L C, Gong S G, Li Y Q, et al. Influence of energy spectrum distribution on drop breakage in turbulent flows[J]. Chemical Engineering Science, 2014, 117: 55-70.
13 Han L C, Gong S G, Ding Y W, et al. Consideration of low viscous droplet breakage in the framework of the wide energy spectrum and the multiple fragments[J]. AIChE Journal, 2015, 61(7): 2147-2168.
14 Solsvik J, Tangen S, Jakobsen H A. On the constitutive equations for fluid particle breakage[J]. Reviews in Chemical Engineering, 2013, 29(5): 241-356.
15 Shi W B, Yang X G, Sommerfeld M, et al. Modelling of mass transfer for gas-liquid two-phase flow in bubble column reactor with a bubble breakage model considering bubble-induced turbulence[J]. Chemical Engineering Journal, 2019, 371: 470-485.
16 Luo P, Wu J, Pan X, et al. Gas-liquid mass transfer behavior in a surface-aerated vessel stirred by a novel long-short blades agitator[J]. AIChE Journal, 2016, 62(4): 1322-1330.
17 Martínez-Delgadillo S A, Alonzo-Garcia A, Mendoza-Escamilla V X, et al. Analysis of the turbulent flow and trailing vortices induced by new design grooved blade impellers in a baffled tank[J]. Chemical Engineering Journal, 2019, 358: 225-235.
18 Mule G M, Kulkarni A A. Mixing of medium viscosity liquids in a stirred tank with fractal impeller[J]. Theoretical Foundations of Chemical Engineering, 2016, 50(6): 914-921.
1 Straathof A J J, Wahl S A, Benjamin K R, et al. Grand research challenges for sustainable industrial biotechnology[J]. Trends in Biotechnology, 2019, 37(10): 1042-1050.
2 Amer B, Baidoo E E K. Omics-driven biotechnology for industrial applications[J]. Frontiers in Bioengineering and Biotechnology, 2021, 9: 613307.
19 Gaddis E S. Mass transfer in gas-liquid contactors[J]. Chemical Engineering and Processing: Process Intensification, 1999, 38(4/5/6): 503-510.
20 Montante G, Horn D, Paglianti A. Gas-liquid flow and bubble size distribution in stirred tanks[J]. Chemical Engineering Science, 2008, 63(8): 2107-2118.
21 Khopkar A R, Rammohan A R, Ranade V V, et al. Gas-liquid flow generated by a Rushton turbine in stirred vessel: CARPT/CT measurements and CFD simulations[J]. Chemical Engineering Science, 2005, 60(8/9): 2215-2229.
22 Sanyal J, Vásquez S, Roy S, et al. Numerical simulation of gas-liquid dynamics in cylindrical bubble column reactors[J]. Chemical Engineering Science, 1999, 54(21): 5071-5083.
23 van Baten J M, Krishna R. CFD simulations of a bubble column operating in the homogeneous and heterogeneous flow regimes[J]. Chemical Engineering & Technology, 2002, 25(11): 1081-1086.
24 Schiller L, Naumann A. A drag coefficient correlation[J]. Zeitschrift des Vereins Deutscher Ingenieure, 1935, 77: 318-320.
25 Orszag S A, Yakhot V, Flannery W S, et al. Renormalization group modeling and turbulence simulations[C]// Proceedings of International Conference on Near-Wall Turbulent Flows. 1993.
26 Prince M J, Blanch H W. Bubble coalescence and break-up in air-sparged bubble columns[J]. AIChE Journal, 1990, 36(10): 1485-1499.
27 Wang T F, Wang J F, Jin Y. A novel theoretical breakup kernel function for bubbles/droplets in a turbulent flow[J]. Chemical Engineering Science, 2003, 58(20): 4629-4637.
28 Garcia-Ochoa F, Gomez E. Bioreactor scale-up and oxygen transfer rate in microbial processes: an overview[J]. Biotechnology Advances, 2009, 27(2): 153-176.
29 Danckwerts P V. Significance of liquid-film coefficients in gas absorption[M]//Insights Into Chemical Engineering. Amsterdam: Elsevier, 1981: 51-75.
30 Kerdouss F, Bannari A, Proulx P, et al. Two-phase mass transfer coefficient prediction in stirred vessel with a CFD model[J]. Computers & Chemical Engineering, 2008, 32(8): 1943-1955.
31 Xiao H, Geng S J, Chen A Q, et al. Bubble formation in continuous liquid phase under industrial jetting conditions[J]. Chemical Engineering Science, 2019, 200: 214-224.
3 Maluta F, Paglianti A, Montante G. Modelling of biohydrogen production in stirred fermenters by computational fluid dynamics[J]. Process Safety and Environmental Protection, 2019, 125: 342-357.
4 Wang H N, Jia X Q, Wang X, et al. CFD modeling of hydrodynamic characteristics of a gas-liquid two-phase stirred tank[J]. Applied Mathematical Modelling, 2014, 38(1): 63-92.
5 Shen X Z, Hibiki T. Bubble coalescence and breakup model evaluation and development for two-phase bubbly flows[J]. International Journal of Multiphase Flow, 2018, 109: 131-149.
6 Zhang X B, Luo Z H. Effects of bubble coalescence and breakup models on the simulation of bubble columns[J]. Chemical Engineering Science, 2020, 226: 115850.
7 Luo H. Coalescence, breakup and liquid circulation in bubble column reactors[D]. Trondheim: Norwegian Institute of Technology, 1993.
[1] 李晨曦, 刘永峰, 张璐, 刘海峰, 宋金瓯, 何旭. O2/CO2氛围下正庚烷的燃烧机理研究[J]. 化工学报, 2023, 74(5): 2157-2169.
[2] 张兰河, 赖青燚, 王铁铮, 关潇卓, 张明爽, 程欣, 徐小惠, 贾艳萍. H2O2对SBR脱氮效率和污泥性能的影响[J]. 化工学报, 2023, 74(5): 2186-2196.
[3] 孙永尧, 高秋英, 曾文广, 王佳铭, 陈艺飞, 周永哲, 贺高红, 阮雪华. 面向含氮油田伴生气提质利用的膜耦合分离工艺设计优化[J]. 化工学报, 2023, 74(5): 2034-2045.
[4] 刘尚豪, 贾胜坤, 罗祎青, 袁希钢. 基于梯度提升决策树的三组元精馏流程结构最优化[J]. 化工学报, 2023, 74(5): 2075-2087.
[5] 周必茂, 许世森, 王肖肖, 刘刚, 李小宇, 任永强, 谭厚章. 烧嘴偏转角度对气化炉渣层分布特性的影响[J]. 化工学报, 2023, 74(5): 1939-1949.
[6] 李正涛, 袁志杰, 贺高红, 姜晓滨. 疏水界面上的NaCl液滴蒸发过程内环流调控机制研究[J]. 化工学报, 2023, 74(5): 1904-1913.
[7] 王泽栋, 石至平, 刘丽艳. 考虑气泡非均匀耗散的矩形反应器声流场数值模拟及结构优化[J]. 化工学报, 2023, 74(5): 1965-1973.
[8] 董鑫, 单永瑞, 刘易诺, 冯颖, 张建伟. 非牛顿流体气泡羽流涡特性数值模拟研究[J]. 化工学报, 2023, 74(5): 1950-1964.
[9] 周艾然, 陆平, 夏建辉, 李冬勤, 郭杰, 杜明, 董立春. 氯化钛白氧化反应器结疤问题分析及数值模拟[J]. 化工学报, 2023, 74(4): 1499-1508.
[10] 李纪元, 李金旺, 周刘伟. 不同扰流结构冷板传热性能研究[J]. 化工学报, 2023, 74(4): 1474-1488.
[11] 许文烜, 江锦波, 彭新, 门日秀, 刘畅, 彭旭东. 宽速域三种典型型槽油气密封泄漏与成膜特性对比研究[J]. 化工学报, 2023, 74(4): 1660-1679.
[12] 陈俊先, 姬忠礼, 赵瑜, 张倩, 周岩, 刘猛, 刘震. 基于微波技术的天然气管道内颗粒物在线检测方法研究[J]. 化工学报, 2023, 74(3): 1042-1053.
[13] 魏进家, 刘蕾, 杨小平. 面向高热流电子器件散热的环路热管研究进展[J]. 化工学报, 2023, 74(1): 60-73.
[14] 王悦琳, 晁伟, 蓝晓程, 莫志朋, 佟淑环, 王铁峰. 合成气生物发酵法制乙醇的研究进展[J]. 化工学报, 2022, 73(8): 3448-3460.
[15] 赵涛岩, 曹江涛, 李平, 冯琳, 商瑀. 区间二型模糊免疫PID在环己烷无催化氧化温度控制系统中的应用[J]. 化工学报, 2022, 73(7): 3166-3173.
Viewed
Full text


Abstract

Cited

  Shared   
  Discussed   
No Suggested Reading articles found!