Scale-up design problem (Rushton turbine): A cylindrical bioreactor holds 100,000 L of liquid (100 m^3) and has an aspect ratio of 2:1 (liquid height to tank diameter). Estimate the appropriate impeller diameter for a Rushton turbine using the common rule D_impeller ≈ one-third of tank diameter.

Difficulty: Medium

Correct Answer: 1.3 m

Explanation:


Introduction / Context:
Estimating impeller diameter is a routine early step in bioreactor specification and scale-up. For Rushton turbines in baffled cylindrical tanks, a common heuristic is D_impeller ≈ 0.33 * D_tank. To use the rule, we must first infer the tank diameter from liquid volume and aspect ratio (height/diameter).


Given Data / Assumptions:

  • Liquid volume V = 100,000 L = 100 m^3.
  • Aspect ratio AR = H / D_tank = 2 : 1, so H = 2 * D_tank.
  • Cylindrical working volume: V = (π * D_tank^2 / 4) * H.
  • Standard Rushton diameter rule: D_impeller ≈ D_tank / 3.


Concept / Approach:
Compute D_tank from the cylinder volume formula using AR = 2. Then apply the one-third rule to obtain the impeller diameter. Finally, map the numerical result to the closest option.


Step-by-Step Solution:

Write V = (π/4) * D_tank^2 * H. With H = 2 * D_tank, V = (π/4) * D_tank^2 * 2 * D_tank = (π/2) * D_tank^3.Solve for D_tank: D_tank = (2 * V / π)^(1/3).Insert V = 100 m^3: D_tank ≈ (200 / π)^(1/3) ≈ 3.99 m (approximately 4.0 m).Apply the rule: D_impeller ≈ D_tank / 3 ≈ 4.0 / 3 ≈ 1.33 m.Choose the closest option: 1.3 m.


Verification / Alternative check:
Check volume using D_tank = 4.0 m and H = 8.0 m: V_calc = π/4 * 4.0^2 * 8.0 ≈ 100.5 m^3 (close to 100 m^3; rounding explains the small difference). The rule-of-thumb then yields D_impeller ≈ 1.33 m, consistent with the selected answer.


Why Other Options Are Wrong:

  • 3.3 m and 5.3 m: these are closer to full tank diameter choices, not one-third.
  • 7.3 m: exceeds the tank diameter implied by the volume.
  • 0.6 m: far below typical one-third sizing; would under-mix.


Common Pitfalls:
Forgetting to convert litres to cubic metres; misinterpreting aspect ratio (height-to-diameter vs diameter-to-height); applying the one-third rule before computing D_tank.


Final Answer:
1.3 m.

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