Computational and experimental investigation of flow and fluid mixing in the roller bottle bioreactor.

The fully three-dimensional velocity field in a roller bottle bioreactor is simulated for two systems (creeping flow and inertial flow conditions) using a control volume-finite element method, and validated experimentally using particle imaging velocimetry. The velocity fields and flow patterns are described in detail using velocity contour plots and tracer particle pathline computations. Bulk fluid mixing in the roller bottle is then examined using a computational fluid tracer program and flow visualization experiments. It is shown that the velocity fields and flow patterns are substantially different for each of these flow cases. For creeping flow conditions the flow streamlines consist of symmetric, closed three-dimensional loops; and for inertial flow conditions, streamlines consist of asymmetric toroidal surfaces. Fluid tracers remain trapped on these streamlines and are unable to contact other regions of the flow domain. As a result, fluid mixing is greatly hindered, especially in the axial direction. The lack of efficient axial mixing is verified computationally and experimentally. Such mixing limitations, however, are readily overcome by introducing a small-amplitude vertical rocking motion that disrupts both symmetry and recirculation, leading to much faster and complete axial mixing. The frequency of such motion is shown to have a significant effect on mixing rate, which is a critical parameter in the overall performance of roller bottles.

Computational and experimental investigation of flow and particle settling in a roller bottle bioreactor.

It is shown that cell settling is a key factor affecting the performance of roller bottle bioreactors. The two-dimensional cross-sectional flow at the center of a roller bottle is simulated using a finite difference method, and the settling behavior of cells is simulated using particle dynamics algorithms and validated experimentally using fluorescent particles. The settling behavior of particles in the roller bottle flow is studied using both steady and time dependent rotation rates. Under steady flow conditions the flow is divided into two regions: one where the particles settle to the wall and one where the particles remain suspended indefinitely. The relative size of these two regions depends on the ratio of the settling velocity to the rotation rate of the bottle. For unsteady flows generated by periodic changes of the bottle rotation direction, the settling of cells is accelerated significantly, leading to complete deposition in just a few turns of the bottle.