Hydrodynamic optimization of a newly designed and fabricated U-Loop bioreactor using Taguchi–ANOVA analysis

IF 3.7 3区生物学 Q2 BIOTECHNOLOGY & APPLIED MICROBIOLOGY

Biochemical Engineering Journal Pub Date : 2026-07-01 Epub Date: 2026-02-23 DOI:10.1016/j.bej.2026.110141

Sohrab Valadbeigy , Mohammad Naghashzadegan , Reza H. Sajedi , Asma Chegeni

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Abstract

This study focuses on the design and hydrodynamic optimization of a newly engineered U-loop bioreactor aimed to improve mixing performance in viscous media for Single-Cell Protein (SCP) production and also compared the Statistical and Practical Optimum which considers industrial condition. Three major innovations were implemented: first, the reduction of pump power to a practical optimum value of 8600 W/m³ and improve mixing efficiency; second, the proposal of optimal operational parameters, including the practical optimum culture medium viscosity of 0.045 Pa.s (0.2-wt% CMC), as an indicator of high SCP concentrations, the optimal inoculum (400 g/Lit), and the optimal static-mixer position ( close to degassing tank inlet); and third, the design and testing of a custom swirl static mixer to enhance circulation and mixing. The effects of these parameters were evaluated using a Taguchi L9 experimental design and ANOVA. The results showed that medium viscosity, was the dominant factor affecting mixing time, followed by pump power and static-mixer position. The experimentally validated statistical optimum configuration of 0-wt% CMC, 96 W pump power, 45-cm static-mixer placement, and 400 g/Lit inoculum results in an average mixing time of 9.9 s, in close agreement with the Taguchi prediction. This study provides a mechanistic and statistically grounded framework for optimizing U-loop bioreactors, offering a solid foundation for SCP production.

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新设计和制造的U-Loop生物反应器流体动力学优化的田口方差分析

为提高单细胞蛋白（SCP）生产中黏性介质的混合性能，对新型u型环型生物反应器进行了设计和流体动力学优化，并比较了考虑工业条件的统计优化和实际优化。实施了三个主要创新：首先，将泵功率降低到8600 W/m3的实用最佳值，提高了混合效率；其次，提出了最佳操作参数，其中实际最佳培养基粘度为0.045 Pa。s (0.2 wt% CMC)，作为高SCP浓度的指标，最佳接种量（400 g/Lit）和最佳静态混合器位置（靠近脱气罐入口）；第三，设计和测试了一种定制的涡流静态混合器，以增强循环和混合。采用田口L9试验设计和方差分析评估这些参数的影响。结果表明，介质粘度是影响搅拌时间的主要因素，其次是泵功率和静态混合器位置。实验验证了0-wt% CMC、96 W泵功率、45 cm静态混合器位置和400 g/Lit接种量的统计最佳配置，平均混合时间为9.9 s，与田口的预测非常吻合。本研究为优化u型环生物反应器提供了一个机制和统计基础框架，为SCP生产提供了坚实的基础。

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来源期刊

Biochemical Engineering Journal 工程技术-工程：化工

CiteScore

7.10

自引率

5.10%

发文量

380

审稿时长

34 days

期刊介绍： The Biochemical Engineering Journal aims to promote progress in the crucial chemical engineering aspects of the development of biological processes associated with everything from raw materials preparation to product recovery relevant to industries as diverse as medical/healthcare, industrial biotechnology, and environmental biotechnology. The Journal welcomes full length original research papers, short communications, and review papers* in the following research fields: Biocatalysis (enzyme or microbial) and biotransformations, including immobilized biocatalyst preparation and kinetics Biosensors and Biodevices including biofabrication and novel fuel cell development Bioseparations including scale-up and protein refolding/renaturation Environmental Bioengineering including bioconversion, bioremediation, and microbial fuel cells Bioreactor Systems including characterization, optimization and scale-up Bioresources and Biorefinery Engineering including biomass conversion, biofuels, bioenergy, and optimization Industrial Biotechnology including specialty chemicals, platform chemicals and neutraceuticals Biomaterials and Tissue Engineering including bioartificial organs, cell encapsulation, and controlled release Cell Culture Engineering (plant, animal or insect cells) including viral vectors, monoclonal antibodies, recombinant proteins, vaccines, and secondary metabolites Cell Therapies and Stem Cells including pluripotent, mesenchymal and hematopoietic stem cells; immunotherapies; tissue-specific differentiation; and cryopreservation Metabolic Engineering, Systems and Synthetic Biology including OMICS, bioinformatics, in silico biology, and metabolic flux analysis Protein Engineering including enzyme engineering and directed evolution.