Abstract
In high-performance industrial fermentation processes, stirring and
aeration may account for significant production costs. Compared to the
widely applied Rushton impellers, axial-pumping impellers are known to
yield a lower power draw and at the same time improve mixing. However,
their lower gas dispersion capability requires stronger agitation,
compromising these benefits. Diverse advanced impeller forms have been
developed to cope with this challenge. We apply alternating radial and
axial impellers and demonstrate strong gas dispersion and
energy-efficient mixing for the first time in a large-scale (160 m
3) bioreactor, based on experimental and CFD
simulation data. For equal operating conditions (stirrer speed, aeration
rate), this setup yielded similar gas hold-ups and better mixing times
(-35 %) compared to a classical Rushton-only configuration. Hence,
applying a radial impeller on an upper level for improving gas
dispersion maintains the benefits of axial impellers in terms of
reducing energy demand (up to -50 %). We conclude that this effect is
significant only at large-scale, when bubbles substantially expand due
to the release of the hydrostatic pressure and have time to coalesce.
The work thus extends current knowledge on mixing and aeration of
large-scale reactors using classical impeller types.