Gas-to-liquid mass transfer is a rate-limiting step for many commercial-scale operations in the chemical, biochemical, pharmaceutical, and wastewater-treatment industries. The use of microbubbles with a diameter on the100 μm scale has been shown to provide high volumetric mass-transfer rates due to its high gas contact area per volume. However, the use of microbubbles in commercial processes has been hampered by the lack of design algorithms with which to fabricate high-performance, microbubble-sparged gas-liquid contacting equipment. The goals of this study were to identify the type of microbubble generator best suited to provide high volumetric mass transfer rates in commercial-scale equipment, characterize the mass-transfer properties, develop models able to predict the mass-transfer rate as a function of the key independent variables, and use the models to develop a design algorithm suitable to use microbubble sparging in industrial processes. The study began with a literature review of microbubble generators that considered factors including the mechanism, safety, cost, and scalability, with the goal of identifying generators suited to cost-effectively provide extremely high mass transfer in commercial-scale equipment. Microbubble generators that used liquid turbulence were found to have the best combination of properties for such applications. In collaboration with the Michigan Biotechnology Institute, a 300-L bioreactor was customized for use with either a RiverForest microbubble ejector and a conventional ring sparger. E.coli batch growth experiments were conducted to compare the growth rates using the two aeration methods. The E.coli growth rate observed during microbubble aeration was about twice that observed with the traditional ring sparger. Mathematical models describing the performance properties of both a microbubble ejector and a Modified Jameson Cell were developed. The models included energy requirements, mass transfer rates, gas and liquid flow patterns, and clearance of spent bubbles. The models predicted that the ejector would be more energy-efficient for applications requiring higher mass-transfer rates and lower gas volume fractions, whereas the Modified Jameson Cell would be more energy-efficient for applications requiring lower mass-transfer rates and higher gas void fractions. Moreover, the ejector generator was considered to have operational advantages over the modified Jameson Cell in terms of surfactant requirement and scalability. Based on these advantages, ejector generators were used for subsequent studies. A novel flow system was developed to measure the mass-transfer rate of microbubble produced by an ejector generator. A mathematical model was developed to reproduce experimental trends and estimate the effective microbubble diameter generated as a function of the gas and liquid flow rates. New axial mixing and two-phase friction factor correlations were developed for the model fidelity. The mathematical model was used to determine the effective microbubble diameter that best reproduced the dissolved oxygen profile for various combinations of gas and liquid velocities. The results were used to develop a correlation to predict the effective microbubble size as a function of system properties. The predictive power of this correlation has utility for industrial process design and scale-up applications. The friction factor and microbubble diameter correlations developed in this study were used to develop additional models to simulate the microbubble mass-transfer in large reactors that are sparged with arrays of microbubble ejectors. The models simulated flow from each ejector using an entrainment model for jet cones. They also simulated arrangement of ejectors into triangular arrays to estimate insufficiently aerated volume and optimize ejector spacing. Collectively, the models developed in this study provide powerful new design tools that enable rational design, optimization, and scale-up of ejector microbubble sparger arrays for commercial-scale reactors that require extremely high volumetric mass-transfer rates.
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