CHAPTER 9: AGITATION AND AERATION ; ADDITIONAL PROBLEM

http://www.chem.mtu.edu/~drshonna/cm4710f07/lectures/chapter10.pdf
A 10,000 liter (of liquid) bioreactor contains 5g/L of growing cells, Q O2 = 20 mmol O2 / (g
cells.hr),DT = 2 m, Di = 1 m, (6 - blade turbine agitator) x 3 blades. For 1 liquid volume per
minute aeration rate (air), can the OTR(oxygen transfer rate) = OUR(oxygen uptake rate) for N =
100 rpm?
GIVEN:
VL=10,000L
QO2 = 20 mmol O2 / (g cells.hr)
DT = 2 m
Di = 1 m
(6 - blade turbine agitator) x 3 blades
N = 100 rpm
REQD: Is OTR = OUR?
SOLN:
Re = Reynold's Number= LNDi2 / L
L= 1000 kg/m3
L =10-3 N.s/m2
Re = (1000 kg/m3)(100/60rps)(1m)2(1N/kg.m/s2) / 10-3 N.s/m2
Re = 1.67x10-6
*Np = 4(from Blanch and Clark Pmo Correlation)
Pmo = 4 (LN3Di5) for 1 impeller
Pmo = 4(1000 kg/m3) (100/60rps)3(1m)5
Pmo = 1.852x104kg.m2.s2/s (watts) x 3(impellers)
Pmo = 5.62x104 watts = 74.5hP
Pm: NA (aeration no.) = Qa / NDi3
NA = (10,000Lpm)(10-3m3/L) / (100min-1)(1m)3

NA = 0.10
*Pm/Pmo = 0.42(from Blanch and Clark NA Correlation)
Pm = (0.42)(5.62x104 Watts)
Pm = 2.335x104 Watts = 31.3hP
kLa (mmol O2 / ( hr.atm) = 0.60(Pm/VL(hP/103 liters))0.4 (Vs)0.5 (N,rpm)0.5
Pm/VL =31.3hP/(10)(103liters) = 3.13hP/103liters
Vs =104 Lpm(103 cm3/L)/

2
2
4 (2m) (10cm/m) = 318.3 cm/min
kLa = 0.60(3.13)0.4 (318.3)0.5 (200)0.5
kLa = 169 (mmol O2 / (hr .atm)

OUR = X qO2 = (5g cells/ L)(20 mmol O2/g cells.hr)

OUR = 100 mmol O2/L.hr

OTR = kLa(PO2 - P*)

P * for CL = 1 mg O2/liter = HO2 CL
= (0.21 atm/(8mg O2/liter))(1 mg O2/liter)
=0.0263 atm
OTR = 169 mmoles O2/liter.hr.atm (0.21 0.0263) atm
OTR = 31.05 mmol O2/liter.hr
*Since OUR > OTR, we must modify the bioreactor operation in order to bring them into
balance
increase N
use pure O2 rather than air.

CHAPTER 9: AGITATION AND AERATION ; ADDITIONAL PROBLEM

Biochemical Engineering, Second Edition by Aiba, S. et.al.

Dimensions of a fermenter equipped with two sets of standard flat-blade turbines and four baffle
plates are:
Fermenter diameter, Dt=3 m
Impeller diameter, Di=1.5 mBaffle plate width, Wb=0.3 m
Liquid depth, HL=5 m
The fermenter is used for a specific fermentation. The viscosity, , and the density, , of the
broth are:
= 1,200 kg/m3, = 0.02 kg/m sec
Rotation speed of impellers and aeration rate are N=60 rpm and 0.4 vvm, respectively.
Calculate:
a.Power requirements, P, for ungassed system,
b. Power requirements, Pg , when aerated,
c.Volumetric coefficient, Kv , of oxygen transfer, and
d. Hold-up, H, of bubbles.
Solution
a.Dt/Di = 3/1.5 = 2.0
HL/Di = 5/1.5 =3.33
N = 1.0 rps
2
n Di 1 1.52 1.2 103
N =
=
=1.35 105
2

2 10
From Fig. 6.5,
Np = 6
3 5
N Di N P 1.2 103 13 1.55 6
P=
=
gc
9.81
5.57 104 kg m/sec 73.3 Hp
Since the geometrical ratios, (Dt/Di)* and (HL/Di)*, of this problem deviate from Dt/Di and HL/Di in
Fig. 6.5, a correction factor, fc, which is approximately expressed as shown below will be
calculated.

DL
H
L
Di
DL

( )( )

( )( )
DL
Di

HL
DL

2.0 3.33
=0.86
3.0 3.0

c=
f
Then,
P P f c =73.3 0.86=63 Hp
If power requirements, P, with two sets of impellers can be estimated by multiplying the value of P for
one set of impellers by 2 (cf. 6.2.2.1.), the total power requirement, P** will be:
P=P2=63 2=126 Hp
P**=126 Hp

b. The aeration number, Na, is calculated as follows:

1
2
0.4 ( ) 3 5 ( )
F
4
60
N a=
=
2
3
n Di
1 1.5
2

6.95 10

Assuming that curve A in Fig. 6.6 can be used,

Pg/P** = 0.65,
Pg = P** 0.65 = 126 0.65 = 82 Hp
Pg=82 Hp

c. F = 0.4 (/4) 32 5 = 14.1 m3/min

14.1 60
v s=
=119.7 m/hr

2
( ) 3
4
From Eq. (6.37).
K v =0.0635 {

82

( ) 32 5
4

0.95

119.70.07

= 3.45 kg mole/m3 hr atm

Supposing that the coefficient, 0.0635 be halved in the case of a flat-blade turbine (cf. Section
7.4., Chapter 7),

Kv = 1.72 kg mole/m3 hr atm

HL/Dt = 5/3 = 1.67
The correction factor, fc, is assumed as follows: (cf. Section 6.3.2.)
fc = 1.3
Then, the volumetric coefficient, Kv*, of oxygen transfer is:
Kv* = Kvfc = 1.72 1.3 = 2.24 kg mole/m3 hr atm
Kv* = 2.24 kg mole/m3 hr atm

It must be remembered that the above value of volumetric coefficient is maximum in terms of
oxygen transfer, because Eq. (6.37) based on the sulfite-oxidation experiment is applied in the
calculation.
d. Fig. 6.7 is used to calculate the hold-up, H.
From Fig. 6.7,
0.4
P 0.4 0.5
126
0.5
( ) v s ={
} 119.7
V

( ) 32 5
4
From an extrapolation of the solid line in Fig. 6.7,
H = 21%

CHAPTER 9: AGITATION AND AERATION ; ADDITIONAL PROBLEM

Biochemical Engineering, Shigeo Katoh and Fumitake Yoshida
In an aerated stirred tank, air is bubbled into degassed water. The oxygen concentration in water
was continuously measured using an oxygen electrode, such that the data in Table 1.0 were
obtained. Evaluate the overall volumetric mass transfer coefficient of oxygen k L (in unit of per
hour). The equilibrium concentration of oxygen in equilibrium with air under atmospheric
pressure is 8.0 mg/L; the delay in response of the oxygen electrode may be neglected.
Table 1.0 Oxygen concentration in water.
Time
(s)
0
20
40
60
80
100
120

O2 concentration (mg/L)
0
2.84
4.63
5.87
6.62
7.10
7.40

Given:
Table 1.0
CL* = 8.0 mg/L
Required: kL
Solution:
From the oxygen balance, the following equation is obtained:
dCL/dt = kL (CL*- CL)
Upon integration with the initial condition CL = 0 at t = 0,

ln [CL*/ (CL*- CL)] = kL (t)

Substituting values from the table; from t = 0 to t = 120
kL = 0.0219/s

CHAPTER 9: AGITATION AND AERATION ; ADDITIONAL PROBLEM

Biochemical Engineering, Shigeo Katoh and Fumitake Yoshida
Calculate the power requirements, with and without aeration, of a 1.5 m-diameter stirred tank,
containing water 1.5 m deep, equipped with a six blade Rushton Turbine that is 0.5 m in diameter
d, with blades 0.25 d long amd 0.2 d wide, operating at a rotational speed of 180 r.p.m. Air is
supplied from the tank bottom at a rate of 0.6 m 3/min. Operation is at room temperature. Values
of water viscosity = 0.001 kg/m.s and water density = 1000 kg/m 3; hence / = = 10 -6 m2/s
can be used.
Given:
Dtank = 1.5 m

= 0.001 kg/m.s

HLiquid = 1.5 m

= 1000 kg/m3

N = 180 r.p.m

/ = = 10-6 m2/s

Q = 0.6 m3/min
Required: Power requirement without aeration, Pmo; Power requirement with aeration, Pm
Solution:
The Power requirement without aeration can be obtained using Figure 1.0.

Figure 1.0 Correlation between Reynolds number (Re) and Power number (Np).
(Re) = (d2 N)/ = (0.52 x 3)/ 10-6 = 7.5 x 105
This is in the turbulent regime. Then from Figure 1.0:
Np = 6
Pmo = 6 N3d5 =6(1000)33(0.5)5 = 5060 kg.m2/s3
Pmo = 5060 W
log (Pm/Pmo) = -192 (1/3)4.38(0.52 x 3/10-6)0.115(0.5 x 32/9.8)1.96/3(0.01/3 x 0.53) = -0.119
Pm/Pmo = 0.760
Hence,
Pm = 5060 x 0.760
Pm = 3850 W

CHAPTER 9: AGITATION AND AERATION ; ADDITIONAL PROBLEM

Biochemical Engineering, Shigeo Katoh and Fumitake Yoshida
A stirred-tank reactor equipped with a standard Rushton turbine of the following dimensions
contains a liquid with density = 1.000 g/cm3 and viscosity = 0.013 g/cm.s. The tank diameter
D = 2.4 m, liquid depth H L = 2.4 m, the impeller diameter d = 0.8 m, and liquid volume = 10.85
m3. Estimate the stirred power required and the mixing time, when the rotational stirrer speed N
is 90 r.p.m., that is 1.5/s.
Given:
= 1.000 g/cm3

= 0.013 g/cm.s

D = 2.4 m

HL = 2.4 m

d = 0.8 m

liquid volume = 10.85 m3

N = 90 r.p.m.
Required: Pm and tm
Solution:
The Reynolds number:
Re = Nd2 / = (1.5 x 802 x 1)/0.013 = 7.38 x 105

Figure 1.0 Correlation between Reynolds number (Re) and Power number (Np).
From Figure 1.0, Np = 6
The power required Pm = (6 x 1.53 x 0.85 x 1000) kg m2/s3
Pm = 6650 W or 6.65 kW

Figure 1.1 Correlations for mixing times (using a standard Rushton turbine).
From figure 1.1, values of N,tm for the above Reynolds number should be about 30. Then,
tm = 30/1.5
tm = 20 seconds

CHAPTER 9: AGITATION AND AERATION ; ADDITIONAL PROBLEM

A fermenter of diameter 3.6m and liquid height of 6.1 m is used for production of ustilagic acid
by Ustilagozeae. The pressure at the top of the fermenter is 1.4 atm. The vessel is stirred using
dual Rushton turbines and the fermentation temperature is 29C. The DO tension is measured
using two electrodes: one is located near the top of the tank, the other is located near the bottom.
Both electrodes are calibrated in situ in sterile culture medium. The DO reading at the top of the
fermenter is 50% air saturation; the reading at the bottom is 65% air saturation. The fermenter is
sparged with air at 20C at flow rate of 30 m 3 min-1 measured at atmospheric pressure. Off-gas
leaving the vessel at a rate of 20.5 m3 min-1 contains 17.2% oxygen. The solubility of oxygen in
the fermentation broth is not significantly different from that in water. The density of the culture
broth is 100 kg/m3.
a. What is the oxygen transfer rate?
b. Estimate the pressure at the bottom of the tank.
c. The gas phase in large fermenters ia assumed to exhibit plug flow. Under these conditions,
no gas mixing occurs so that the gas phase composition at the bottom of the tank is equal to
that in the inlet gas stream, while the gas composition at the top of the tank is equal to that in
the outlet gas stream. For the gas phase in plug flow, estimate the oxygen solubility at the top
and bottom of the tank.
d. What is the value of kLa?
e. If the cell concentration is 16 g/L, what is the specific oxygen demand?

f. Industrial fermentation vessels are rated for operation at elevated pressures so they can
withstand steam sterilization. Accordingly, the fermenter used for ustilagic acid production
can be operated safely at a maximum pressure of 2.7 atm abs. assuming that respiration by U.
zeae and the value of kLa are relatively insensitive to pressure, what maximum cell
concentration can be supported by oxygen transfer in the fermenter after pressure is raised?
Given:
DT = 3.6m
HL= 6.1 m
Qin=30 m3 min-1
Qout=20.5 m3 min-1
= 1000 kg/m3
CO2,in = 50%
CO2,out = 65%
Solution:
a. OTR =

V=

Required:
a. OTR
b. Pbottom
c. CL*bottom, CL*top
d. kLa
e. Specific O2 demand
f. CL*at Pmax = 2.7 atm abs

qA
V = Qin CO2,in - Qout CO2,out

DT2 HL =

qA
V =

(3 .6m) (6.1 m) = 62. 0904 m3

1 QP ( 0.21 ) Qout P ( %O2 )

[

]
RV
Tin
Tout

qA
V =

atm
0.08205 L.
. K (60.0904 m 3)
mol

m3
( 30minm3 ) ( 1 atm ) (0.21) (20.5 min
)( 1.4 atm ) (0.172)
(20+273)

(29+273)

qA
3 mol
=1.0458 x 10
V
Lmin
b. PT = 1.4 atm + PL
PL = gh = (1000 kg/m3) (9.81 m/s2) (6.1m)

1 atm
101325 Pa

= 0.5906 atm

PT = 1.4 atm + 0.5906 atm

PT = 1.9906 atm
c. Inlet at 20C & 1 atm

[ ] [ ]
P02
CL

inlet

P02
CL

bottom

][

1 atm(o .21)
1atm
=
1.38 mol /L
CL

C L =0.2898mol / L

Outlet at 29C & 1.4 atm

][

1 atm(o .21)
1atm
=
1.38 mol /L
CL

C L =0.2841mol / L

d. kLa =

qA
V
C L C L

mol 1000 mmol

Lmin
1 mol
mmol
( 0.15 ) 0.2841
0
L

1.0458 x 103
kLa =

kLa = 24.5407 /min

e. Q if V=16 g/L , MW O2 = 32 g/mol

Q=

mol 32 g
L min mol
=
16 g/ L

1.0458 x 103

( )

2.0916 x 10-3 /min

PM
=
RT

( 1 atm ) 32

g
mol

)( 1000kg g )

L atm (
1 m3
0.08205
29+273 ) K
mol K
1000 L

= 1.2914 kg/m3

Sp. O2 demand= (2.0916 x 10-3/min) (1.2914 kg/m3)

Sp. O2 demand = 2.7011 x 10-3 kg/m3min
f. Pmax = 2.7 atm abs
2.7 atm ( 0.172 )
=
CL

][

1atm
mmol
1.18
L

C L =0.5480mmol /L

CHAPTER 9: AGITATION AND AERATION ; ADDITIONAL PROBLEM

Calculate the maximum possible rate of oxygen uptake at 37C of microorganisms having a
diameter of 2/3 m suspended in an agitated aqueous solution. It is assumed that the surrounding
liquid is saturated with 02 from air at 1 atm pressure. It will be assumed that the microorganism

can utilize the oxygen much faster that it can diffuse it. The microorganism has a density very
close to that of water.
Given:
T = 37 C
Dp = 2/3 m
PO2 = 1 atm
= 999.9999 kg/m3
Required: Maximum O2 uptake
Solution:
Additional info: CO2 surface = 2.26 x10-4 kmol/m3 @ saturation
DAB @ PO2, inH20 = 3.25 x 10 -9 m2/s
Convective Mass Transfer over a spherical surface
hm D p
0.25
=2+0.43 ( GT AB S C )
D AB
hm D p
=2+ 0
D AB

hm =

2 D AB 2 ( 3.25 x 109 m2 /s )
=
DP
2
x 106 m
3

= 9.7695

x 103 m/s

Flux O2 :
nO2 =hm (CO2; CO2 surface)
= (9.7695

x 10 m/s (2.26 x10-4 kmol/m3 0)

nO2 = 2.2034 x10-6 kmol/ m2s

CHAPTER 9: AGITATION AND AERATION ; ADDITIONAL PROBLEM

A 200-L stirred fermenter contains a batch culture of Bacillus subtilis bacteria at 28C. Air at
20C is pumped into the vessel at a rate of 1 vvm. The average pressure in the fermenter is 1 atm.
The volumetric flow rate of off-gas from the fermenter is measured as 189 L/min. The exit gas

stream is analyzed for oxygen and is found to contain 20.1% O 2. The dissolved oxygen
concentration in the broth is measured using an oxygen electrode as 52% saturation. The
solubility of oxygen in the fermentation broth at 28C and 1 atm air pressure is 7.8x10-3 kg/m3.
a. Calculate the Oxygen Transfer Rate
b. Determine the kLa for the system
Given:
Vmed=200L
Tmed=28C
Tair = 20C
Qair = 1 vvm
P=1 atm
Qgas = 189 L/min
O2 out= 20.1% O2
Solubility of O2 @ 1 atm, 28C = 7.8x10-3 kg/m3

Required:
a. OTR
b. kLa

Solution:

1
[ F Cinlet FC outlet ]
VL

a. NA=

CO2,inlet =

CO2,outlet =

NA =

0.21(1 atm)
-3
L atm
0.08205
( 20+273.15 ) K = 8.7352 x10 mol/L
mol K

0.201 atm
-3
L atm
0.08205
( 28+273.15 ) K = 8.1386 x10 mol/L
mol K

1
mol
L
mol
( 200 L ) ( 1 vvm ) 8.7352 x 103
189
8.1386 x 103
200 L
L
min
L

)(

)(

NA= 1.0442 x 10-3 mol/L.min

b. kLa =

NA
C L C L

(1.0442 x 10

kLa =

kLa = 0.1487 s-1

mol
L . min

L 32 kg
kmol
1 min
)( 1000
(
)(
)(
)
kmol 1000 mol 60 s )
m
3

7.8 x 103( 0.52 ) (7.8 x 103 )

)]

CHAPTER 9: AGITATION AND AERATION ; ADDITIONAL PROBLEM

A bioreactor (DT = 3 m) contains 1000 L of liquid (water) and 15 g / L of growing cells whose
respiration rate is 25 mmole O2 / g cells-hr. It is being agitated by three turbine-type impellers at
25 OC and 1 atm. State where the reaction is biochemically limited or mass transfer limited for N
= 60 rpm and 1 vvm. Assume P m/Pmo = 0.5; L = 1,000 kg / m3; L = 1 x 10-3 kg/m-s. It has also
been determined experimentally that the diameter of air bubbles is 5 x 10 -2 m and its velocity is
0.5 m/s.
Given:
VR = 1000 L; Cx = 15g/L; qO2 = 25 mmole O2 / g cells-hr; DT = 3 m; Pm/Pmo = 0.5; L = 1,000 kg /
m3; L = 1 x 10-3 kg/m-s; Dbubbles = 5 x 10-2 m; Velocitybubbles = 0.5 m/s

Required:
Is the reaction biochemically limited or mass transfer limited?

Solution:
From James Lee Chapter 6, Di= (1/3)DT = (1/3) (3m) = 1 m
Re = Reynold's Number = L N Di2 / L
Re = (1,000 kg/m3)(60/60s)(1m)2 / (1 x 10-3 kg/m-s) = 1 x 106
From figure 9.8 of James M. Lee: Power number = 6 = Pmo / (L N3 Di5)
Pmo = 6 (L N3 Di5)
= 6 [(1,000 kg/m3)(60/60s-1)3(1m)5]
= 6000 (Watts)
Pmo (3 impellers) = 3 (6000 Watts) = 18000 Watts
Pm = 0.5 (Pmo) = (0.5)(18000 Watts) = 9000 Watts
From equation 9.71 of James Lee: kLa (s-1) = 0.026 [(Pm/VR)]0.4 (vs)0.5
Pm/VR = 9000 Watts/1m3 = 9000 Watts/m3
HT = (1m3)/ [(/4)(3m)2] = 0.1415 m
vs = [(6)(1000 L/ min)(1min/60s)(1 m3/1000 L)( 0.1415 m)] / [(5 x 10-2 m)(0.5 m/s)(1 m3)]

= 0.566 m-1
kLa = 0.026 [9000]0.4 (0.566)0.5= 0.7466 s-1
Oxygen Transfer Rate, OTR = kLa(CL* - CL)
From table 9.1 of James Lee: CL*@pure oxygen = 1.26 mmoles O2 / L
CL* = (0.21atm)/ [(1atm)/(1.26 mmoles O2 / L)] = 0.1667 mmoles O2 / L
OTR = (0.7466 s-1)(3600s/hr) (0.1667-0) mmoles O2 / L
OTR = 448.0398 mmoles O2 / L-hr
Oxygen Uptake Rate = Cx qO2 = (15 g cells/L) (25 mmoles O2/g cells-hr)
OUR = 375 mmoles O2 / L-hr

Therefore, since OUR < OTR, the reaction is BIOCHEMICALLY LIMITED!