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Gas dispersion in non-Newtonian fluids has numerous applications in many chemical and biochemical applications. However, the effect of the power-law model constants describing the rheological behavior of the pseudoplastic fluid has never been investigated. Thus, a numerical model was developed to simulate the hydrodynamics of gas dispersion in non-Newtonian fluids with a coaxial mixer. Then, a set of experiments was conducted to assess the mass transfer efficacy of a coaxial mixer to benchmark the numerical model. In this regard, various methods, including dynamic gassing-in and electrical resistance tomography methods, were used to quantify the mass transfer and gas hold-up profiles. The influence of fluid rheological properties, gas flow number, and rotating mode on the power consumption, mass transfer coefficient, bubble size profile, and hydrodynamics were examined both experimentally and numerically. The response surface model (RSM) was employed to explore the individual effects of power-law model constants on mass transfer. The RSM model utilized five levels for the consistency index (k), five levels for the flow index (n), and three levels for the gas flow number. The statistical model proposed that the absolute model constants for the flow and consistency indices were 0.0012 and 0.0010, respectively, for the co-rotating mixer. Conversely, for the counter-rotating mixer, these constants were 0.0010 and 0.0013, respectively. Therefore, this study revealed that the co-rotating coaxial mixer was well-suited for dispersing gas within a fluid with high consistency. In contrast, the counter-rotating mixer proved effective in enhancing gas dispersion within a fluid with a lower flow index. [ABSTRACT FROM AUTHOR]

Coaxial bioreactors are known for effectively dispersing gas inside non-Newtonian fluids. However, due to their design complexity, many aspects of their design and function, including the relationship between hydrodynamics and bioreactor efficiency, remain unexplored. Nowadays, various numerical models, such as computational fluid dynamics (CFD) and artificial intelligence models, provide exceptional opportunities to investigate the performance of coaxial bioreactors. For the first time, this study applied various machine learning models, both classifiers and regressors, to predict the torque generated by a coaxial bioreactor. In this regard, 500 CFD simulations at different aeration rates, central impeller speeds, anchor impeller speeds, and rotating modes were conducted. The results obtained from the CFD simulations were used to train and test the machine learning models. Careful feature scaling and k-fold cross-validation were performed to enhance all models' performance and prevent overfitting. A key finding of the study was the importance of selecting the right features for the model. It turns out that just by knowing the speed of the central impeller and the torque generated by the coaxial bioreactor, the rotating mode can be labelled with perfect accuracy using k-nearest neighbors (kNN) or support vector machine models. Moreover, regression models, including multi-layer perceptron, kNN, and random forest, were examined to predict the torque of the coaxial impellers. The results showed that the random forest model outperformed all other models. Finally, the feature importance analysis indicated that the rotating mode was the most significant parameter in determining the torque value. [ABSTRACT FROM AUTHOR]

Aerated stirred vessels are commonly employed to enhance gas dispersion. However, the associated high energy consumption is a challenging feature, particularly when dealing with complex non‐Newtonian fluids. Coaxial mixers comprising a central impeller and a close‐clearance impeller have emerged as an energy‐efficient alternative that effectively intensifies gas dispersion. Hence, the objective of this study is to investigate the effect of aeration and agitation on the gas dispersion effectiveness of a coaxial mixer containing a yield‐pseudoplastic fluid. An anchor‐pitched blade turbine was employed to disperse air into a 1 wt.% xanthan gum solution, and the analysis primarily focused on characterizing the gas holdup and fluid flow behaviour. Gas holdup data were obtained experimentally using electrical resistance tomography (ERT), while computational fluid dynamics (CFD) simulations provided a detailed analysis of fluid flow patterns within the coaxial mixer. The rotational speed of the impeller exhibited a non‐monotonic effect on the gas holdup, and a significant influence of the interaction between variables was identified. For instance, the experimental data showed that the aeration effect varied with the anchor speed. Nevertheless, the variables' interaction effect was explained by the change in flow pattern observed numerically. Furthermore, the CFD results demonstrated that high gas holdup does not necessarily indicate intensified mixing. Therefore, combining experimental data and numerical simulations enables a more accurate characterization of mixing performance. These findings contribute to the understanding and improvement of mixing performance in such a complex system, which is crucial for designing efficient operations. [ABSTRACT FROM AUTHOR]

For the aeration of highly viscous non-Newtonian fluids, prior studies have demonstrated the improved efficacy of dual coaxial mixing bioreactors fitted with two central impellers and a close clearance anchor. Evaluating the effectiveness of these bioreactors involves considering various mixing characteristics, with a specific emphasis on shear rate distribution. The study of shear rate distribution is critical due to its significant impact on the mixing performance, gas dispersion, and homogeneity in aerated mixing systems comprising shear-thinning fluids. Although yield-pseudoplastic fluids are commonly employed in various industries, there is a research gap when it comes to evaluating shear rate distribution in aerated mixing bioreactors that utilize this fluid type. This study aims to investigate shear rate distribution in an aerated double coaxial bioreactor that handles a 1 wt% xanthan gum solution, known as a Herschel–Bulkley fluid. To achieve this goal, we employed an experimentally validated computational fluid dynamics (CFD) model to assess the effect of different mixing configurations, including down-pumping and co-rotating (Down-Co), up-pumping and co-rotating (Up-Co), down-pumping and counter-rotating (Down-Counter), and up-pumping and counter-rotating (Up-Counter) modes, on the shear rate distribution within the coaxial mixing bioreactor. Our findings revealed that the Up-Co system led to a more uniform local shear distribution and improved mixing performance. [ABSTRACT FROM AUTHOR]

Alternate energy resources need to be developed to amend for depleting fossil fuel reserves. Lignocellulosic biomass is a globally available renewable feedstock that contains a rich sugar platform that can be converted into bioethanol through appropriate processing. The key steps of the process, pretreatment, enzymatic hydrolysis, and fermentation, have undergone considerable amount of research and development over the past decades nearing the process to commercialization. In order for the commercialization to be successful, the process needs to be operated at high dry matter content of biomass, especially in the enzymatic hydrolysis stage that influences ethanol concentration in the final fermentation broth. Biomass becomes a thick paste with challenging rheology for mixing to be effective. As the biomass consistency increases, yield stress increases which limits efficiency of mixing with conventional stirred tanks. The purpose of this review is to provide features and perspectives on processing of biomass into ethanol. Emphasis is placed on rheology and mixing of biomass in the enzymatic hydrolysis step as one of the forefront issues in the field.

Coaxial mixers have been shown to be effective in enhancing the hydrodynamic stress and shear environment inside the aerated systems. However, the scale-up study of the aerated coaxial mixing reactors based on a constant mass transfer coefficient has never been reported in the literature. In this study, for the first time, a practical technique is suggested to evaluate the scalability of these systems in terms of a constant mass transfer coefficient. The effects of impeller speed, impeller type, aeration rate, and pumping direction on the mass transfer, power consumption, gas holdup profile, fluid hydrodynamics, and energy dissipation rate were explored for gas dispersion in non-Newtonian fluids inside coaxial mixers through tomography, dynamic gassing-in, and computational fluid dynamics. It was found that a practical approach to preserve the mass transfer coefficient of the large-scale coaxial mixer the same as its small-scale counterpart was to maintain the volumetric aeration rate per working fluid volume constant. [ABSTRACT FROM AUTHOR]