Tutorial on Scale-Up

(a) The following expression for a fully baffled stirred bioreactor with a single impeller has
been derived by dimensionless analysis:

𝑁𝑝 = 𝑐(𝑁𝑅𝑒 ) 𝜒

where Np is power number

N Re is Reynold’s number
c is a constant dependent on vessel geometry
𝜒 is an exponent

Plots of power number against Reynolds number on log-log coordinates for

various bioreactor configurations based on Figure 1 can be constructed from
experimentally obtained data as in Figure 2, with the value of the exponent 𝜒
changing with flow regimes. Explain the significance of these curves in terms of
scaling up a fermentation process in geometrically similar bioreactors in each
of laminar, transient, and turbulent regions.

Figure 1 (5 marks)

(b) A fermentation process in a pilot-scale stirred-tank bioreactor with four baffles

and two impellers each comprising of a disc with six vertical flat-blade impellers
with dimensions as below was found to produce the maximum yield when the
impeller speed was N = 0.27 rps.

Dt (Fermenter diameter) = 1.00 m

Da (Impeller diameter) = 0.33 m
E (Height of lowest impeller) = 0.33 m
L (Length of blade) = 0.0825 m
W (Width of blade) = 0.066 m
J (Baffle width) = 0.10 m
H (Distance between impellers) = 1.00 m

The fermentation broth fulfilled the criteria for a Newtonian fluid throughout the
fermentation, and has the following characteristics:

Density   1300 kgm 3

Viscosity   0.03 kgm 1s 1

The following relationships apply:

𝑁𝑝 = 𝜌𝑁𝑃30𝐷5 Power number

𝑎

𝑃0 = 𝑐𝜌𝑁 3 𝐷𝑎5 (turbulent flow)

𝑃0 = 𝑐𝜇𝑁 2 𝐷𝑎3 (laminar flow)

2
𝑁𝑅𝑒 = 𝜌𝑁𝐷
𝜇
𝑎 Reynold’s number

where  = liquid density

 = liquid viscosity
N = impeller rotational speed

𝐷𝑎 = impeller diameter

Po = power consumption for un-gassed fluid

You are required to scale-up this fermentation process using the method of
‘constant power per unit volume’ to a geometrically similar production-scale
bioreactor 50 times its volume. Estimate the impeller speed of the production-
scale bioreactor.

A log-log graph paper is provided in the Appendix 1.

(25 marks)
Figure 2.
Solution
(a) This typical power curve can be divided up into 3 clearly defined regions, as shown in
Fig. 2 and described in Table 1 below:

Table 1: Regions in a Power Curve

Region Reynolds number Slope of plot ( )
Laminar flow <101 -1
Transition 101 - 104 Variable
Turbulent flow >104 0

The Reynolds number is thus a criterion for the degree of turbulence within the system and
may be used to reveal the flow regime which exist.
(3 Marks)

If the experimentally determined value of the exponent  are substituted into equation 1, the
following expressions results:

P  cN 3 D 5 (turbulent flow)

P  cN 2 D 3 (laminar flow)

These two equations are widely used to predict the effects of operating variables upon power
consumption in scale-up of fermentation based on un-gassed fluids.
(2 Marks)

(b) From the dimensions given, we can determine, which curve on the plot of Np against
Rei that corresponds to curve A.

Check if the system is in the transition flow region:

Calculate the value of the Reynolds number (NRe) on the small scale under the defined
optimal conditions.

N i Da2
Rei =

Where Ni = impeller speed of agitation in rps = 0.27 rps.
 Da (Impeller diameter) = 0.33 m

Density   1300 kgm 3

Viscosity   0.03 kgm 1s 1

N i Da2 1300  0.27  0.332

Therefore, Rei =  = 1,274.13
 0.03

The value of Reynolds no. indicates that the flow is in the transition region.
The following procedure can be used for scale-up in the transition region:
(ii) Find the corresponding value of the power number at small scale (N P1) by
interpolating the power curve.
From the power curve, the corresponding value of NP1 is 4.8.
With two impellers, NP1 = 2 × 4.8 = 9.6
(iii) Calculate power of the small scale from power number equation:

P1  N P1 N13 D15

 P = 9.6 × 1300 × 0.273 × 0.335 = 0.96 W

(iv) Calculate the required power consumption on the large scale:

V 
P2  P1 *  2  = 0.96 * 50 = 48 W
 V1 
(v) For the large fermenter, calculate values of the Reynolds number over a range
of different impeller speed :

 N 2 D22 
N Re   
  

First, what is the value of D22 ?

1
 Di   V1  3
For geometrically similar vessels,  1  
 Di   V2 
 2 
1
V 3
 D   2  Di1  503  0.33  1.2m
1

 V1 

Now, calculate values of the Reynolds number over a range of different impeller speeds:
 Ni(2) Rei(2)

0.025 1560

0.050 3120

0.075 4680
Transition
0.100 6240 Region

0.125 7800

0.150 9360

0.175 10920
Turbulent
0.200 12480 Region

Presumably the speed of agitation is between 0.1 and 0.17 because they fall in the
transition region.
(vi) Find the values of the power numbers corresponding to these Reynolds
numbers by interpolating the power curve.
Ni(2) Rei(2) Np

0.025 1560 4.8

0.050 3120 5.4

0.075 4680 5.8

0.100 6240 6.0

0.125 7800 6.0

0.150 9360 6.0

0.175 10920 6.0

0.200 12480 6.0

(vii) Calculate the power consumption on the large scale at each selected value of
impeller speed from the normal power number equation:
P2  N P 2 N 23 D25

Since the large scale is geometrically the same with the small scale, hence with
2 impellers, NP(2) = 2 × NP (obtained from the curve). Therefore,
 Ni(2) Np 2Np  Da(2) Ni(2)3 Da(2)5 P2 log Ni(2) log (P2)

0.025 4.8 9.6 1300 1.2 0.0000156 2.488 0.485 -1.60 -0.31

0.05 5.4 10.8 1300 1.2 0.000125 2.488 4.367 -1.30 0.64

0.075 5.8 11.6 1300 1.2 0.000422 2.488 15.830 -1.12 1.20

0.1 6 12 1300 1.2 0.001000 2.488 38.818 -1.00 1.59

0.125 6 12 1300 1.2 0.001953 2.488 75.816 -0.90 1.88

0.15 6 12 1300 1.2 0.00338 2.488 131.010 -0.82 2.12

0.175 6 12 1300 1.2 0.005 2.488 208.039 -0.76 2.32

0.107334 6 12 1300 1.2 0.001 2.488 48.000 -0.97 1.68

(vii) Plot power consumption against impeller speed on log-log coordinates for the
large fermenter.
Or use Goal Seek in Excel to determine what is the value of Impeller speed that
corresponds to P2 = 48 W.

From Goal Seek, we shall obtain the Ni2 = 0.107 rps.

Or Solve using the normal calculation, by substituting the values of P2 as 48 W into

the power no equation.

P2  N P 2 N 23 D25
48  12.0  1300  N 23  1.25
48  38816 N 23
N 23  1.237  10 3
N 2  3 1.237  10 3  0.107 rps

From the curve of P2 against Ni(2), at P2 =48 W, the value of Ni(2) was found to be
0.107rps. And from the plot of log P2 against log Ni(2), at log 48 = 1.68, the value
of log Ni(2) was found to be -0.96. Therefore, the value of Ni(2) is 10-0.96 = 0.107 rps.
4.8

Re = 1,274.13
QUESTION 2

(PO2, PO6, CO3, C3, C3, C5)

Two geometrically similar stirred tanks with a flat-blade turbine impeller of the following
dimensions are to be operated at 30C as pilot-scale and production-scale aerobic
fermenters.

Scale Impeller diameter, Di Liquid volume, V (m 3) Tank diameter (m)

(m)
Pilot 0.24 0.17 0.50
Production 0.8 6.28 1.6

Satisfactory results were obtained with the pilot-scale fermentor at a rotational impeller
speed Ni of 1.5 s-1 and volumetric air flow rate, Q of 0.0083 m3 s-1. The density and
viscosity of the broth are 1050 kgm-3 and 0.002 kg/m.s, respectively. Van’t Riet (1979)
has discovered a correlation for oxygen mass transfer coefficient, k La as the scale-up
criterion in relation with the following equations:

−3
𝑃𝑎 0.7 0.2
𝑘𝐿 𝑎 = 2.0 × 10 ( ) 𝑣𝑠
𝑉
−0.20
𝑃𝑎 𝑄 −0.25 𝑁𝑖2 𝐷𝑖4
= 0.10 ( ) ( )
𝑃0 𝑁𝑖 𝑉 𝑔𝑊𝑖 𝑉 2⁄3
where
Pa = aerated power (W)
vs = superficial gas velocity (m/s)
Wi = impeller blade width
P0 = power consumption for unaerated bioreactor.
g = gravitational acceleration = 9.81 ms-2

(a) By referring to Curve 1 in Fig. 3, calculate the Reynolds number and hence determine the
power consumption of aerated bioreactor at pilot scale.

The following relationships apply:

𝑁𝑝 = 𝜌𝑁𝑃30𝐷5 Power number

𝑎
 𝑃0 = 𝑐𝜌𝑁 3 𝐷𝑎5 (turbulent flow)

𝑃0 = 𝑐𝜇𝑁 2 𝐷𝑎3 (laminar flow)

2
𝑁𝑅𝑒 = 𝜌𝑁𝐷
𝜇
𝑎 Reynold’s number

where  = liquid density

 = liquid viscosity
N = impeller rotational speed

𝐷𝑎 = impeller diameter

Po = power consumption for ungassed fluid

(7 marks)

Figure 3. The power number-Reynolds number relationship for various impellers.

(b) Calculate the superficial gas velocity, vs and estimate the oxygen mass transfer
𝑄
coefficient, kLa for pilot scale. Given that 𝜐𝑠 =
𝐴

where A = cross-sectional area of the bioreactor, Q = volumetric flowrate of air

sparged into the fermentor,
(5 marks)

(c) Estimate the kLa for the production scale by employing constant superficial gas
velocity and constant power consumption per unit volume as scale up criteria and
comment on the value obtained in comparison with the value of k La in (b).

Given that, correlation for speed of agitation in terms of volume is

2⁄
𝑁2 𝑉1 9
=( )
𝑁1 𝑉2

The subscript 1 and 2 refer to pilot scale and production scale, respectively.
(15 marks)

Solution:
(i)
𝑁𝐷2𝑎 1050×1.5×0.242
𝑁𝑅𝑒 = 𝜇 = = 45,360 (turbulent flow)
0.002

(2 marks)
From Curve 1 in Fig. 1,
Np = 5

Then power consumption for un-aerated bioreactor, 𝑃 = 𝑁𝑝 𝜌𝑁 3 𝐷𝑎5

5 × 1050 × 1.53 × 0.245 = 14 W. (1 marks)

Then the aerated power consumption can be calculated by the given formula;
 −0.20
𝑃𝑎 𝑄 −0.25 𝑁𝑖2 𝐷𝑖4
= 0.10 ( ) ( )
𝑃 𝑁𝑖 𝑉 𝑔𝑊𝑖 𝑉 2⁄3
−0.20
𝑃𝑎 0.0083 −0.25 1.52 ×0.244
 = 0.10 ( ) ( 2 ) =
𝑃 1.5×0.17
9.81𝑊𝑖 ×0.173
0.024 −0.20
0.10(2.35) ( ) (1 mark)
9.81𝑊𝑖
𝑊𝑖
Given that, = 0.2 (1 mark)
𝐷𝑖

Therefore, Wi = 0.2Di = 0.2 × 0.24 = 0.048 m (1 mark)

By substituting P = 14 W and Wi = 0.048 m into the above equation,

𝑃𝑎 0.024 −0.20
 = (0.235) ( ) = 0.426
14 9.81×0.048

Then, Pa = 14 × 0.426 = 5.97 W. (1 mark)

ii) Cross-sectional area of the stirred tank, given that DT = 0.5 m

𝐷𝑇2 0.52
A=𝜋 =𝜋 =0.196 m2
4 4

𝑄 0.0083
Then, 𝜐𝑠 = = = 0.042 𝑚/𝑠 (2 marks)
𝐴 0.196

hence,
−3
𝑃𝑎 0.7 0.2
𝑘𝐿 𝑎 = 2.0 × 10 ( ) 𝑣𝑠
𝑉

−3
5.97 0.7
𝑘𝐿 𝑎 = 2.0 × 10 ( ) 0.0420.2
0.17

𝑘𝐿 𝑎 = 2.0 × 10−3 × 12.07 × 0.53 = 0.0128𝑠 −1 (3 marks)

(iii) The rotational speed of agitator for production scale can be determined from,
 2⁄
𝑁2 𝑉1 9
=( )
𝑁1 𝑉2
2⁄
𝑁2 0.17 9
=( )
1.5 6.28

N2 = 0.67 rps (3 marks)

From constant power consumption for unaerated bioreactor per unit volume where,

P1 P
 2
V1 V2
𝑃 14
Then P2 = 𝑉1 𝑉2 = 0.17 (6.28) = 517 𝑊
1
(2 marks)

Then the aerated power consumption can be calculated by the given formula;
−0.20
𝑃𝑎 𝑄 −0.25 𝑁𝑖2 𝐷𝑖4
= 0.10 ( ) ( )
𝑃 𝑁𝑖 𝑉 𝑔𝑊𝑖 𝑉 2⁄3

𝑄
From the constant superficial gas velocity, 𝜐𝑠 = 𝐴2 = 0.042𝑚/𝑠
2

𝐷𝑇2 1.62
where A2 = 𝜋 =𝜋 =2 m2
4 4

Therefore, Q2 = A2vs = 2 × 0.042 = 0.084 m3/s (2

marks)

−0.20
𝑃𝑎 0.084 −0.25 0.672 ×0.84
 = 0.10 ( ) ( 2 ) =
𝑃 0.67×6.28
9.81𝑊𝑖 ×6.283
0.054 −0.20
0.10(2.66) ( )
9.81𝑊𝑖
𝑊𝑖
Given that, = 0.2
𝐷𝑖

Therefore, Wi = 0.2Di = 0.2 × 0.8 = 0.16 m

By substituting P = 517 W and Wi = 0.16 m into the above equation,

𝑃𝑎 0.054 −0.20
 = (0.266) ( ) = 0.52
517 9.81×0.16

Then, Pa = 517 × 0.52 = 269.8 W. (4 marks)

hence,
−3
𝑃𝑎 0.7 0.2
𝑘𝐿 𝑎 = 2.0 × 10 ( ) 𝑣𝑠
𝑉

−3
269.8 0.7
𝑘𝐿 𝑎 = 2.0 × 10 ( ) 0.0420.2
6.28

𝑘𝐿 𝑎 = 2.0 × 10−3 × 13.876 × 0.53 = 0.0147𝑠 −1 (1 mark)

Percentage error between the 2 kLa values are defined by,

(0.0147−0.0128)
× 100 = 14.8% (1 mark)
0.0128

Theoretically, the two values should be similar, however, it is very difficult to

achieve a constant kLa values because of the correlation (Van’t Riet) used here
is very general that applies to this calculation. In addition, the aeration in larger
scale will consume more power and cost that will affect the kLa values.

(2 marks)