Optimization of oxygen transfer and power consumption in aerobic bioprocess by designing disc turbine impeller based on CFD-Taguchi method
Abstract Disc turbine impeller serves as a vital component of stirred-tank bioreactors and plays crucial role in optimizing their performance. This research integrates Computational Fluid Dynamics (CFD) with Taguchi experimental method to analyze the effects of blade curvature, asymmetry, and radial...
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Nature Portfolio
2025-03-01
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| Online Access: | https://doi.org/10.1038/s41598-025-92463-1 |
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| author | Qingfeng Gu Sainan Yang Ali Mohsin Junxiong Yu Yingping Zhuang Chao Li |
| author_facet | Qingfeng Gu Sainan Yang Ali Mohsin Junxiong Yu Yingping Zhuang Chao Li |
| author_sort | Qingfeng Gu |
| collection | DOAJ |
| description | Abstract Disc turbine impeller serves as a vital component of stirred-tank bioreactors and plays crucial role in optimizing their performance. This research integrates Computational Fluid Dynamics (CFD) with Taguchi experimental method to analyze the effects of blade curvature, asymmetry, and radial bending angles on disc turbine impeller performance. The designed P-0.1-T15B20-AM30° impeller maximizes the objective function $${E}_{V}$$ , balancing volumetric oxygen transfer coefficient $${k}_{L}a$$ and power input per unit volume $$P/V$$ . Statistical analysis revealed that blade curvature significantly affected $${k}_{L}a$$ and $$P/V$$ , blade asymmetry substantially impacted $$P/V$$ and $${E}_{V}$$ , and the radial bending angle exhibited a notable influence on $${k}_{L}a$$ , $$P/V$$ , and $${E}_{V}$$ . The P-0.1-T15B20-AM30° impeller sustains an average oxygen transfer efficiency of 52.3% equivalent to that of the Rushton turbine (RT) impeller and 68.9% akin to the CD-6 impeller, while its average energy consumption is merely 31.2% and 46.1% of the RT and CD-6 impellers, respectively. The average $${E}_{V}$$ of the P-0.1-T15B20-AM30° impeller is enhanced by 12.4% and 8% in comparison to the RT and CD-6 impellers, respectively. Conclusively, these results demonstrate that the P-0.1-T15B20-AM30° impeller offers economic and practical advantages in aerobic bioprocesses and presents new perspectives for advancing impeller design. |
| format | Article |
| id | doaj-art-4faf89b2b57c4531938d6732e0806228 |
| institution | DOAJ |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj-art-4faf89b2b57c4531938d6732e08062282025-08-20T03:05:52ZengNature PortfolioScientific Reports2045-23222025-03-0115112410.1038/s41598-025-92463-1Optimization of oxygen transfer and power consumption in aerobic bioprocess by designing disc turbine impeller based on CFD-Taguchi methodQingfeng Gu0Sainan Yang1Ali Mohsin2Junxiong Yu3Yingping Zhuang4Chao Li5State Key Laboratory of Bioreactor Engineering, East China University of Science and TechnologyState Key Laboratory of Bioreactor Engineering, East China University of Science and TechnologyState Key Laboratory of Bioreactor Engineering, East China University of Science and TechnologyState Key Laboratory of Bioreactor Engineering, East China University of Science and TechnologyState Key Laboratory of Bioreactor Engineering, East China University of Science and TechnologyState Key Laboratory of Bioreactor Engineering, East China University of Science and TechnologyAbstract Disc turbine impeller serves as a vital component of stirred-tank bioreactors and plays crucial role in optimizing their performance. This research integrates Computational Fluid Dynamics (CFD) with Taguchi experimental method to analyze the effects of blade curvature, asymmetry, and radial bending angles on disc turbine impeller performance. The designed P-0.1-T15B20-AM30° impeller maximizes the objective function $${E}_{V}$$ , balancing volumetric oxygen transfer coefficient $${k}_{L}a$$ and power input per unit volume $$P/V$$ . Statistical analysis revealed that blade curvature significantly affected $${k}_{L}a$$ and $$P/V$$ , blade asymmetry substantially impacted $$P/V$$ and $${E}_{V}$$ , and the radial bending angle exhibited a notable influence on $${k}_{L}a$$ , $$P/V$$ , and $${E}_{V}$$ . The P-0.1-T15B20-AM30° impeller sustains an average oxygen transfer efficiency of 52.3% equivalent to that of the Rushton turbine (RT) impeller and 68.9% akin to the CD-6 impeller, while its average energy consumption is merely 31.2% and 46.1% of the RT and CD-6 impellers, respectively. The average $${E}_{V}$$ of the P-0.1-T15B20-AM30° impeller is enhanced by 12.4% and 8% in comparison to the RT and CD-6 impellers, respectively. Conclusively, these results demonstrate that the P-0.1-T15B20-AM30° impeller offers economic and practical advantages in aerobic bioprocesses and presents new perspectives for advancing impeller design.https://doi.org/10.1038/s41598-025-92463-1Aerobic bioprocessComputational fluid dynamicsDisc turbine impellerOxygen transferPower consumptionTaguchi method |
| spellingShingle | Qingfeng Gu Sainan Yang Ali Mohsin Junxiong Yu Yingping Zhuang Chao Li Optimization of oxygen transfer and power consumption in aerobic bioprocess by designing disc turbine impeller based on CFD-Taguchi method Scientific Reports Aerobic bioprocess Computational fluid dynamics Disc turbine impeller Oxygen transfer Power consumption Taguchi method |
| title | Optimization of oxygen transfer and power consumption in aerobic bioprocess by designing disc turbine impeller based on CFD-Taguchi method |
| title_full | Optimization of oxygen transfer and power consumption in aerobic bioprocess by designing disc turbine impeller based on CFD-Taguchi method |
| title_fullStr | Optimization of oxygen transfer and power consumption in aerobic bioprocess by designing disc turbine impeller based on CFD-Taguchi method |
| title_full_unstemmed | Optimization of oxygen transfer and power consumption in aerobic bioprocess by designing disc turbine impeller based on CFD-Taguchi method |
| title_short | Optimization of oxygen transfer and power consumption in aerobic bioprocess by designing disc turbine impeller based on CFD-Taguchi method |
| title_sort | optimization of oxygen transfer and power consumption in aerobic bioprocess by designing disc turbine impeller based on cfd taguchi method |
| topic | Aerobic bioprocess Computational fluid dynamics Disc turbine impeller Oxygen transfer Power consumption Taguchi method |
| url | https://doi.org/10.1038/s41598-025-92463-1 |
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