A novel bioreactor developed for the intensification of high-viscosity aerobic fermentation processes

To address the common challenges of inadequate substrate mixing, restricted oxygen transfer, and low energy efficiency in high-viscosity aerobic fermentation systems, a dedicated bioreactor equipped with a microporous spiral impeller was developed. The bioreactor features an axial–radial composite flow field design that overcomes the single-shear limitation of conventional impellers. Experimental data and CFD simulations indicate that, compared with bioreactors fitted with Rushton impellers, the novel system achieves significantly enhanced gas–liquid mass transfer and increases energy efficiency by 1.6–2.9 times. Furthermore, the universality of the platform has been validated with four representative biopolymers, including proteins and polysaccharides. This technology is the first to achieve synergistic optimization of mixing–mass transfer–energy efficiency in high-viscosity aerobic fermentation. This approach provides a platform-based, cross-disciplinary solution for biomanufacturing processes with high-viscosity aerobic characteristics without requiring genetic modification.