CFD Modelling Validated by PIV of Hydrodynamics in a Raceway Bioreactor: Dead Zone Detection and Flow Field Analysis

Raceway bioreactors are widely employed for microalgal production owing to their low construction and operational costs, in addition to their scalability benefits. Nonetheless, limited hydrodynamic studies are corroborated by computer models that have been experimentally validated. This paper delineates the methodology and validation of a computational fluid dynamics (CFD) model for a 10 L laboratory-scale Raceway bioreactor operating under abiotic conditions. In ANSYS Fluent, a multiphase technique was used with the RNG k-ε turbulence model, which is good for simulating flows that are curved or rotating in open-channels. Experimental validation was performed using Particle Image Velocimetry (PIV) at paddlewheel velocities of 20, 25, and 30 rpm. The CFD predictions showed a strong match with the experimental data, with a mean relative error of less than 8%. The examination of the flow field revealed the formation and subsequent reduction of low-velocity zones, depending on the intensity of agitation. Based on study on velocity distribution and Reynolds number, it was suggested that the design be changed so that the paddlewheel be moved to improve flow homogeneity without increasing energy use. The validated CFD model provides a reliable basis for improving the hydrodynamics, design, and operation of Raceway bioreactors. Additionally, it serves as a foundation for future research on biomass cultivation and expansion, facilitating the development of more efficient and sustainable microalgal production technologies.