Mixing operations in biological processes is of utmost importance due to its effect on scaling-up and heat and mass transfer. This paper presents the characterization of a bench-top bioreactor with different impeller configurations, agitation and oxygen transfer rates, using CFD simulations and experimental procedures. Here, it is demonstrated that factors such as the type of impeller and the flow regime can drastically vary the operation as in the preparation of cultures. It was observed that the bioreactor equipped with a Rushton generates a $k_{L}a$ of 0.0056 s⁻¹ for an agitation velocity and airflow rate of 250 RPM and 5 L/min, respectively. It is suitable result for the dissolved oxygen (DO) but requires a considerable amount of power consumption. It is here where the importance of the agitator’s diameter can be observed, since, in the case of the two propeller types studied, lower energy consumption can be achieved with a smaller diameter, as well as a much smaller shear cup 2.376 against 0.723 s⁻¹ by decreasing by 4 cm the standard diameter of an agitated tank (10 cm). Finally, the $k_{L}a$ values obtained for the different configurations are compared with the maximum shear rate values of different cell cultures to highlight the impact of this study and its applicability to different industries that use agitation processes for cell growth.

Solutions that aim to reduce water production in heavy oil wells have led to the design of devices known as rate-controlled production (RCP) autonomous inflow-control device (AICD) valves, which are placed in well completions and autonomously open with the oil inflow and close with water by choking the flow. These devices, which are based on Bernoulli’s principle, use a levitating disk that chokes the flow of the phase with the lowest flow resistance. This study proposes a numerical model based on computational fluid dynamics (CFD) technology to understand these devices’ operations and propose better designs without experimentation. The numerical model was based on dynamic fluid–body interaction (DFBI) and volume of fluid (VOF) models. The model was found to respond as expected depending on the physical properties of the fluids involved in heavy oil production. Finally, some limitations were found in the numerical study that can be improved in future studies.