EXPERIMENT-5 MIXING TIME DETERMINATION.

Mixing, a physical process which aims at reducing non-uniformities in fluids by eliminating gradients
of concentration, temperature, and other properties, is happening within every bioreactor. It is so
important that, in a very large extend, decides the performance of a bioreactor. When mixing is
beneficial to bioprocesses, for example, the contact of substrate and other nutrients to cells during
cell culture, we should try to improve the mixing performance of a bioreactor through all kinds of
means. Otherwise, we should avoid its negative effects.

Mixing time is a useful parameter for assessing mixing efficiency and is applied to characterize bulk
flow in fermenters. The mixing time tm is the time required to achieve a given degree of
homogeneity starting from the completely segregated state. It can be measured by injecting a tracer
into the vessel and following its concentration at a fixed point in the tank. Tracers in common use
include acids, bases and concentrated salt solutions; corresponding detectors are pH probes and
conductivity cells.

Mixing time can also be determined by measuring the temperature response after addition
of a small quantity of heated liquid. Definition of the mixing time tm depends on the degree
of homogeneity required. Usually, mixing time is defined as the time after which the
concentration of tracer differs from the finial concentration Cf by less than 10% of the total
concentration difference (Cf−Ci). At tm the tracer concentration is relatively steady and the
fluid composition approaches uniformity. For a single-phase liquid in a stirred tank with
several baffles and small impeller, there is an approximate relationship between mixing
time and circulation time ,tm = 4tc.

We can predict that mixing time in stirred tanks will depend on variables such as the size of the tank
and impeller, fluid properties such as viscosity, and stirred speed. The relationship between mixing
time and several of these variables has been determined experimentally for different impellers; The
dimensionless number Ni t m is plotted as a function of the impeller Reynolds number (Re )i. tm is
the mixing time based on a 10% deviation from final conditions, and Ni is rotational speed of the
stirrer. Ni tm represents the number of stirrer rotations required to homogenize the liquid.

Usually, electrical power is used to drive impellers in stirred tanks. For a given stirred speed, the
power required depends on the resistance offered by the fluid to rotation of the impeller. Average
power consumption per unit volume for industrial bioreactors ranges from 10 kW m − 3 for small
vessels to 1~2 kW m − 3 for large vessels. Friction in the stirrer motor gearbox and seals reduces the
energy transmitted to the fluid; therefore, the electrical power consumed by stirrer motors is always
greater than the mixing power by an amount depending on the efficiency of the drive. Energy costs
for operation of stirrers in bioreactors are an important consideration in process economics.

Sometimes, it is impossible to reduce mixing times by simply raising the power input into the stirrer.
So, while increasing the stirrer speed is an obvious way of improving fluid circulation, other
techniques may be required. Mixing can be improved by changing the configuration of the system.
Baffles should be installed; this is routine for stirrer fermenters and produces greater turbulence. For
efficient mixing the impeller should be mounted below the geometric center of the vessel. In
standard designs the impeller is located about one impeller diameter, or one-third the tank
diameter, above the bottom of the tank.

Mixing is facilitated when circulation currents below the impeller are smaller than those above; fluid
particles leaving the impeller at the same time instant then take different periods of time to return
and exchange material. Rate of distribution throughout the vessel is increased when upper and
lower circulation loops are asynchronous. Another device for improving mixing is multiple impellers,
although this requires an increase in power input. Typical bioreactors used for aerobic culture are
tall cylindrical vessels with liquid depths significantly greater than the tank diameter. This design
produces a higher hydrostatic pressure at the bottom of the vessel, and gives rising air bubbles a
longer contact time with liquid. Effective mixing in tall fermenters requires more than one impeller.