Computational fluid dynamics analysis of mixing and gas–liquid mass transfer in wave bag bioreactor

Abstract Single use bioreactors provide an attractive alternative to traditional deep‐tank stainless steel bioreactors in process development and more recently manufacturing process. Wave bag bioreactors, in particular, have shown potential applications for cultivation of shear sensitive human and animal cells. However, the lack of knowledge about the complex fluid flow environment prevailing in wave bag bioreactors has so far hampered the development of a scientific rationale for their scale up. In this study, we use computational fluid dynamics (CFD) to investigate the details of the flow field in a 20‐L wave bag bioreactor as a function of rocking angle and rocking speed. The results are presented in terms of local and mean velocities, mixing, and energy dissipation rates, which are used to create a process engineering framework for the scale‐up of wave bag bioreactors. Proof‐of‐concept analysis of mixing and fluid flow in the 20‐L wave bag bioreactor demonstrates the applicability of the CFD methodology and the temporal and spatial energy dissipation rates integrated and averaged over the liquid volume in the bag provide the means to correlate experimental volumetric oxygen transfer rates (k L a) data with power per unit volume. This correlation could be used as a rule of thumb for scaling up and down the wave bag bioreactors.