Modeling Multiphase Heat and Mass Transfer in an Agitated Filter Dryer by Integrating Experiment, Computations, and Analytical Solutions.

The drying of a wet cake consisting of an active pharmaceutical ingredient and solvent in an agitated filter-dryer is a critical and challenging unit operation in the pharmaceutical industry. The complexity of this operation is attributed to the constraints on product quality in terms of its physical properties in addition to the residual solvent content. In this manuscript, a better understanding of the drying mechanism is gained by integrating insights from three-dimensional analytical solutions and computational fluid dynamics simulations into a zero-dimensional model to explain experimental data. The approach provides the time evolution of the mass flow rate of solvent from the wet cake and the center-point temperature of the cake with good accuracy. Further investigation of the zero-dimensional model reveals important parameters such as the mass transfer rate number that predicts whether the process is convection-controlled or diffusion-controlled, and the thermal load of vaporization that estimates the fraction of solvent vaporized per unit time. These parameters can be useful in devising a drying protocol for agitated-filter dryers.

Carbon monoxide mass transfer for syngas fermentation in a stirred tank reactor with dual impeller configurations.

This study compares the power demand and gas-liquid volumetric mass transfer coefficient, kLa, in a stirred tank reactor (STR) (T = 0.211 m) using different impeller designs and schemes in a carbon monoxide-water system, which is applicable to synthesis gas (syngas) fermentation. Eleven different impeller schemes were tested over a range of operating conditions typically associated with the "after large cavity" region (ALC) of a Rushton-type turbine (D/T = 0.35). It is found that the dual Rushton-type impeller scheme exhibits the highest volumetric mass transfer rates for all operating conditions; however, it also displays the lowest mass transfer performance (defined as the volumetric mass transfer coefficient per unit power input) for all conditions due to its high power consumption. Dual impeller schemes with an axial flow impeller as the top impeller show improved mass transfer rates without dramatic increases in power draw. At high gas flow rates, dual impeller schemes with a lower concave impeller have kLa values similar to those of the Rushton-type dual impeller schemes but show improved mass transfer performance. It is believed that the mass transfer performance can be further enhanced for the bottom concave impeller schemes by operating at conditions beyond the ALC region defined for Rushton-type impellers because the concave impeller can handle higher gas flow rates prior to flooding.

Measuring carbon monoxide gas-liquid mass transfer in a stirred tank reactor for syngas fermentation.

Carbon monoxide-liquid mass transfer rates in a water-filled stirred tank reactor are determined using a myoglobin protein method to measure dissolved carbon monoxide concentrations as a function of time. Data are acquired over a range of stirrer speeds (200 < or = N < or = 600 rpm) and gas flow rates (1 < or = Q < or = 6 L/min), corresponding to a gas retention time range of 1.2-7 min. Volumetric CO-water mass transfer coefficients range from 0.003 to 0.043 s(-1) and are well-correlated using the power density and the superficial gas velocity.

Growth of Rhodospirillum rubrum on synthesis gas: conversion of CO to H2 and poly-beta-hydroxyalkanoate.

To examine the potential use of synthesis gas as a carbon and energy source in fermentation processes, Rhodospirillum rubrum was cultured on synthesis gas generated from discarded seed corn. The growth rates, growth and poly-beta-hydroxyalkanoates (PHA) yields, and CO oxidation/H(2) evolution rates were evaluated in comparison to the rates observed with an artificial synthesis gas mixture. Depending on the gas conditioning system used, synthesis gas either stimulated or inhibited CO-oxidation rates compared to the observations with the artificial synthesis gas mixture. Inhibitory and stimulatory compounds in synthesis gas could be removed by the addition of activated charcoal, char-tar, or char-ash filters (char, tar, and ash are gasification residues). In batch fermentations, approximately 1.4 mol CO was oxidized per day per g cell protein with the production of 0.75 mol H(2) and 340 mg PHA per day per g cell protein. The PHA produced from R. rubrum grown on synthesis gas was composed of 86% beta-hydroxybutyrate and 14% beta-hydroxyvalerate. Mass transfer of CO into the liquid phase was determined as the rate-limiting step in the fermentation.