Matthieu Dreyer

Surface wave dynamics in orbital shaken cylindrical containers

Be it to aerate a glass of wine before tasting, to accelerate a chemical reaction, or to cultivate cells in suspension, the “swirling” (or orbital shaking) of a container ensures good mixing and gas exchange in an efficient and simple way. Despite being used in a large range of applications this intuitive motion is far from being understood and presents a richness of patterns and behaviors which has not yet been reported. The present research charts the evolution of the waves with the operating parameters identifying a large variety of patterns, ranging from single and multiple crested waves to breaking waves. Free surface and velocity fields measurements are compared to a potential sloshing model, highlighting the existence of various flow regimes. Our research assesses the importance of the modal response of the shaken liquids, laying the foundations for a rigorous mixing optimization of the orbital agitation in its applications.

Efficient and reproducible mammalian cell bioprocesses without probes and controllers

Bioprocesses for recombinant protein production with mammalian cells are typically controlled for several physicochemical parameters including the pH and dissolved oxygen concentration (DO) of the culture medium. Here we studied whether these controls are necessary for efficient and reproducible bioprocesses in an orbitally shaken bioreactor (OSR). Mixing, gas transfer, and volumetric power consumption (P(V)) were determined in both a 5-L OSR and a 3-L stirred-tank bioreactor (STR). The two cultivation systems had a similar mixing intensity, but the STR had a lower volumetric mass transfer coefficient of oxygen (k(L)a) and a higher P(V) than the OSR. Recombinant CHO cell lines expressing either tumor necrosis factor receptor as an Fc fusion protein (TNFR:Fc) or an anti-RhesusD monoclonal antibody were cultivated in the two systems. The 5-L OSR was operated in an incubator shaker with 5% CO(2) in the gas environment but without pH and DO control whereas the STR was operated with or without pH and DO control. Higher cell densities and recombinant protein titers were obtained in the OSR as compared to both the controlled and the non-controlled STRs. To test the reproducibility of a bioprocess in a non-controlled OSR, the two CHO cell lines were each cultivated in parallel in six 5-L OSRs. Similar cell densities, cell viabilities, and recombinant protein titers along with similar pH and DO profiles were achieved in each group of replicates. Our study demonstrated that bioprocesses can be performed in OSRs without pH or DO control in a highly reproducible manner, at least at the scale of operation studied here.

RANS and LES computations of the tip-leakage vortex for different gap widths

In hydraulic turbines, the tip-leakage vortex is responsible for flow instabilities and for promoting erosion due to cavitation. To better understand the tip vortex flow, Reynolds- averaged Navier–Stokes (RANS) and large eddy simulation (LES) computations are carried out to simulate the flow around a NACA0009 blade including the gap between the tip and the wall. The main focus of the study is to understand the influence of the gap width on the development of the tip vortex, as for instance its trajectory. The RANS computations are performed using the open source solver OpenFOAM 2.1.0, two incidences and five gaps are considered. The LESs are achieved using the YALES2 solver for one incidence and two gaps. The validation of the results is performed by comparisons with experimental data available downstream the trailing edge. The position of the vortex core, the mean velocity and the mean axial vorticity fields are compared at three different downstream locations. The results show that the mean behaviour of the tip vortex is well captured by the RANS and LES computations compared to the experiment. The LES results are also analysed to bring out the influence of the gap width on the development of the tip-leakage vortex. Finally, a law that matches the vortex trajectory from the leading edge to the mid-chord is proposed. Such a law can be helpful to determine, in case of cavitation, if the tip vortex will interact with the walls and cause erosion.

Hydrodynamic stress in orbitally shaken bioreactors.

Orbitally shaken bioreactors (OSRs) of nominal volume from 50 mL to 2’000 L have been developed for the cultivation of suspension-adapted mammalian cells. Here we study the hydrodynamics of OSRs for mammalian cells. The results are expected to allow the determination of key parameters for cell cultivation conditions and will facilitate the scale-up of OSRs.

Mind the gap - tip leakage vortex in axial turbines

The tendency of designing large Kaplan turbines with a continuous increase of output power is bringing to the front the cavitation erosion issue. Due to the flow in the gap between the runner and the discharge ring, axial turbine blades may develop the so called tip leakage vortex (TLV) cavitation with negative consequences. Such vortices may interact strongly with the wake of guide vanes leading to their multiple collapses and rebounds. If the vortex trajectory remains close to the blade tip, these collapses may lead to severe erosion. One is still unable today to predict its occurrence and development in axial turbines with acceptable accuracy. Numerical flow simulations as well as the actual scale-up rules from small to large scales are unreliable. The present work addresses this problematic in a simplified case study representing TLV cavitation to better understand its sensitivity to the gap width. A Naca0009 hydrofoil is used as a generic blade in the test section of EPFL cavitation tunnel. A sliding mounting support allowing an adjustable gap between the blade tip and wall was manufactured. The vortex trajectory is visualized with a high speed camera and appropriate lighting. The three dimensional velocity field induced by the TLV is investigated using stereo particle image velocimetry. We have taken into account the vortex wandering in the image processing to obtain accurate measurements of the vortex properties. The measurements were performed in three planes located downstream of the hydrofoil for different values of the flow velocity, the incidence angle and the gap width. The results clearly reveal a strong influence of the gap width on both trajectory and intensity of the tip leakage vortex.

Interaction of a pulsating vortex rope with the local velocity field in a Francis turbine draft tube

Acoustic resonances in Francis turbines often define undesirable limitations to their operating ranges at high load. The knowledge of the mechanisms governing the onset and the sustenance of these instabilities in the swirling flow leaving the runner is essential for the development of a reliable hydroacoustic model for the prediction of system stability. The present work seeks to study experimentally the unstable draft tube flow by conducting a series of measurements on a reduced Francis Turbine model. The key physical parameters and their interaction with the hydraulic and mechanical system are studied and quantified. In particular, the evolution of the axial and tangential velocity components in the draft tube cone is analysed by means of Laser Doppler Anemometry. Combined with the calculation of the instantaneous vortex rope volume based on flow visualization and the measurement of the pressure fluctuations, the nature of the auto-oscillation in the draft tube flow is investigated.

RANS computations of tip vortex cavitation

The present study is related to the development of the tip vortex cavitation in Kaplan turbines. The investigation is carried out on a simplified test case consisting of a NACA0009 blade with a gap between the blade tip and the side wall. Computations with and without cavitation are performed using a RANS modelling and a transport equation for the liquid volume fraction. Compared with experimental data, the RANS computations turn out to be able to capture accurately the development of the tip vortex. The simulations have also highlighted the influence of cavitation on the tip vortex trajectory.