The model can then be used for further parametric studies for the purpose of design optimization, specifically for changing operating conditions such as sparge gas flow rate and impeller speed. One bioreactor computational fluid dynamics model is created and solved to simulate three different operating conditions. Operating parameters (i.e., impeller speed, gas sparge rate) for the mesh-independent and benchmarked computational fluid dynamics models are then changed, and a comparison is made between the computational fluid dynamics model prediction and experimental data. In particular, the oxygen transfer rate, k La, is the primary performance parameter of interest, and to ensure the validity of the solutions, a mesh-independent computational fluid dynamics model is benchmarked against an experimentally determined k La. The goal of this article is to provide a method for simulating and analyzing impeller mixing and gas sparging in a bioreactor using multiphase computational fluid dynamics modeling. Furthermore, individual parameters within CFD simulations can be varied with precision to facilitate design optimization with results interpreted at a level that is often masked by natural variation in physical testing. The advantage of computational fluid dynamics is that it enables rapid and cost-effective simulation of various conditions and provides detailed visual data that can complement or exceed experimental methods. Parametric studies on process conditions provide valuable insight for early-stage bioreactor design and process development.
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