Liquid‐Solid Mass Transfer Behavior of a New Stirred‐Tank Reactor with a Packed Bed Fixed to its Wall

Rates of liquid‐solid mass transfer at a packed bed of Raschig rings fixed to the wall of a stirred tank were measured by a technique which involves the diffusion‐controlled dissolution of copper in acidified dichromate. Variables studied were impeller rotation speed, impeller geometry, Raschig ring diameter, bed thickness, presence of baffles, physical properties of the solution, and effect of superimposed flow. Mass transfer data for the batch reactor were correlated by a dimensionless equation. For a given set of conditions, the radial‐flow impeller was found to produce higher rates of mass transfer than the axial‐flow impeller. The presence of baffles increased the rate of mass transfer inside the bed. Applications of the suggested reactor in conducting different diffusion‐controlled liquid‐solid reactions were evaluated.     

Oxygen Transfer in a Baffled Rectangular Air‐Lift Loop Reactor

The objective of this study is to characterize mass transfer in a rectangular air‐lift loop reactor in two‐phase flow. In a previous work, it has been shown that the reactor presents a complex gas flow pattern. Therefore, first, the global mass transfer volumetric coefficient k_La was measured in two‐phase flow, by three methods (two based on the liquid phase mass balance, one based on the gas phase mass balance). Then, second, a localized analysis was implemented in order to obtain more information about the phenomena governing the gas phase flow.     

Liquid‐Solid Mass Transfer Behavior of a Stirred‐Tank Reactor with a Fixed Bed at Its Bottom

The mass transfer behavior of a new batch stirred tank with a fixed bed of Raschig rings at the bottom was studied using diffusion‐controlled dissolution of copper in acidified dichromate. Variables studied, amongst others, were the impeller rotation speed, Raschig ring diameter, fixed‐bed height, and impeller geometry. The rate of mass transfer from the fixed bed to the solution increased with increasing impeller rotation speed, decreasing particle size, and decreasing bed height. The axial‐flow turbine is more efficient in increasing the rate of mass transfer than the radial‐flow turbine. The presented reactor is especially useful for conducting diffusion‐controlled liquid‐solid catalytic reactions involving reactants that need to be dispersed first, such as sparingly soluble solid particles.     

Influence of Bubble Bouncing on Mass Transfer and Chemical Reaction

The hydrodynamics of bubbly flows is dominated by bubble‐induced turbulence and bubble‐bubble interactions. Both phenomena influence the gas‐liquid mass transfer as well as the mixing of reactants. If the time scales of mass transfer and mixing are in the same order as the time scales of a parallel‐consecutive reaction, the yield and selectivity will be affected by the local hydrodynamics. An experimental setup is presented that enables the investigation of mass transfer during well‐defined and adjustable bubble collisions. The influence of CO₂ bubble collisions on mass transfer is measured and modeled with a modified Sherwood number correlation. Further visualization of the concentration field in the vicinity of O₂ bubbles by means of laser‐induced fluorescence demonstrates the dependency of mass transfer from a chemical reaction and permits the development of a first model approach.     

Toward Understanding of Two‐Phase Eccentric Helical Reactor Performance

Mass transfer investigations in a two‐phase gas‐liquid Couette‐Taylor flow (CTF) reactor and a numerical flow simulation are reported. The CTF reactor is characterized by high values of the mass transfer parameters. Previous mass transfer investigations have yielded high values of the volumetric mass transfer coefficients (of the order of 10^–1 s^–1) and the specific interfacial area, compared to those obtained in a stirred tank (10³ m² m^–3). In order to intensify mass transfer in the CTF reactor, an eccentric rotor (rotating inner cylinder) was used. In the eccentric annulus with rotating inner cylinder, due to frequent variation of the hydrodynamic flow field parameters, nonlinear hydrodynamic conditions occurred. These conditions can influence the rate of mass transfer. The experimental results of benzaldehyde oxidation in an eccentric CTF reactor confirmed an increase in mass transfer, as against a concentric CTF reactor. Numerical simulation of the Couette‐Taylor (helical) flow was performed in a concentric and in an eccentric annulus. Calculation of parameters such as velocity, static pressure, kinetic energy and energy dissipation rate revealed a significant effect of gap eccentricity on the flow behavior.     

Practical Experience in Design and Operation of Liquid‐Liquid Extraction Processes

Liquid‐liquid (L/L) extraction is a standard unit operation in the phenol‐acetone process. Special applications are the extraction of phenol from process water and the removal of phenol from recycle cumene. Besides the standard equipment such as static mixers and horizontal settlers, centrifugal pumps are used for mixing and vertical settlers are operated for phase separation. This article covers some practical experience in design and operation with focus on using centrifugal pumps, maintain mass transfer in pipes and the design of vertical settlers. Gaps in knowledge about various phenomena such as the mass transfer in turbulent L/L pipe flow are pointed out.     

How Do Vortex Structures Influence Boundary Layer Dynamics in Gas‐Liquid Systems?

In many process engineering applications, the dynamics of gas‐liquid two‐phase flows plays a crucial role. The transfer of mass from the gaseous phase into the liquid phase is often a limiting step. This communication deals with the question how vortex structures, which are ubiquitous in engineering fluid flows, influence the transport processes of mass and momentum close to the interface. The question is approached by means of a methodical series of experiments with increasing optical access. By utilizing particle image velocimetry and laser‐induced fluorescence, detailed investigations of hydrodynamics and mass transfer are carried out.     

Hydrodynamics and Mass Transfer in Gas‐Liquid‐Solid Circulating Fluidized Beds

Although extensive work has been performed on the hydrodynamics and gas‐liquid mass transfer in conventional three‐phase fluidized beds, relevant documented reports on gas‐liquid‐solid circulating fluidized beds (GLSCFBs) are scarce. In this work, the radial distribution of gas and solid holdups were investigated at two axial positions in a GLSCFB. The results show that gas bubbles and solid particles distribute uniformly in the axial direction but non‐uniformly in the radial direction. The radial non‐uniformity demonstrates a strong factor on the gas‐liquid mass transfer coefficients. A local mass transfer model is proposed to describe the gas‐liquid mass transfer at various radial positions. The local mass transfer coefficients appear to be symmetric about the central line of the riser with a lower value in the wall region. The effects of gas flow rates, particle circulating rates and liquid velocities on gas‐liquid mass transfer have also been investigated.     

Effects of Contaminants on the Mass‐Transfer Characteristics of a Two‐Impinging‐Streams Gas‐Liquid Reactor

The mass‐transfer characteristics of a new type of two‐impinging‐streams reactor (TISR) was studied by means of sodium sulfite solution as the liquid phase and air as the gas phase, in the presence and absence of various types of surface‐active agents (SAAs). The influences of anionic, cationic, and nonionic SAAs on the specific interfacial area and overall volumetric mass‐transfer coefficient obtained in the TISR were investigated. It was found that the presence of a little amount of the above‐mentioned contaminants increases the specific interfacial area and decreases the overall volumetric mass‐transfer coefficient. On the basis of the experimental results obtained for various types of SAAs, correlations were derived for the interfacial area as well as the Sherwood number for the liquid phase in terms of Froude, Reynolds, Schmidt, and Morton numbers.     

Structured Porous Millireactors for Liquid‐Liquid Chemical Reactions

Milli‐scale reactors with an integrated microstructure offer a promising scale‐up approach for conventional microreactors. This study applies 3D‐printed structured porous millireactors to industrially relevant liquid‐liquid reactions. The underlying transport mechanisms are identified by quantifying interfacial heat and mass transfer. The structured reactors perform limited in Taylor flow compared to a packed‐bed reactor due to limited interfacial mass transfer. However, in stratified flow, their productivity increases significantly at a fraction of the pressure drop of a packed bed.     

Scale‐down des Strahlzonen‐Schlaufenreaktors: Entwicklung eines Screening‐Tools für transportlimitierte chemische Reaktionen

The jet zone loop reactor (JZR) is a high performance loop reactor in which it was shown on different reactions that the use of multiscale transport phenomena leads to a significant increase in the space‐time yield and selectivity. As the use of a JZR in a semi‐industrial scale means a high effort, the development of a comparable screening tool in a laboratory scale is the logical step in which the new technology can be estimated easily and quickly. Experimental hydrodynamic studies of the laboratory reactor showed that significant integral and local parameters are similar to the reactor in semi‐industrial scale, so that the reactor could be used to study a consecutive fast chlorination.     

Two‐Phase Flow with Mass Transfer in Bubble Columns

Bubble columns are widely used in the chemical and biochemical industries. In these reactors a gaseous phase is dispersed into a continuous liquid phase thus the rising bubble swarm induces a circulating flow field. For the dimension of these reactors the local interfacial area and the residence time of the liquid and the gaseous phase are key parameters. In this paper an Euler‐Euler approach is used to calculate the flow field in bubble columns numerically. Therefore a transport equation for the mean bubble volume based on a population balance equation approach is coupled with the balance equations for mass and momentum. The calculations are performed for three‐dimensional, instationary flow fields in cylindrical bubble columns considering the homogeneous and the heterogeneous flow regime. For the interphase mass transfer the physical absorption of the gaseous phase into the liquid is assumed. The back mixing in the gaseous and liquid phase is calculated from the local and time dependent concentration of a tracer.     

Liquid‐Solid Mass Transfer Behavior of a Vertical Array of Closely Spaced Horizontal Tubes in Relation to Catalytic and Electrochemical Reactor Design

The rates of mass transfer at a vertical array of closely spaced horizontal tubes were measured by the limiting‐current technique under single‐phase flow, gas sparging and two‐phase flow. The single‐phase flow data were correlated by the equation: Sh = 0.75 Sc^0.33 Re^0.59. The gas sparging data with no net solution flow were correlated by the equation: J = 0.31(Re_g.Fr)^–0.22. For two‐phase flow, the gas flow was found to enhance the rate of array mass transfer by a factor ranging from 1.25 to 5.25, depending on Re_g and Re. The enhancement ratio increases with decreasing Re and increasing Re_g. For Re ≥ 2500, the rate of mass transfer approaches the value of single‐phase flow, regardless of the value of Re_g, which ranged from 7 to 41. The importance of the present geometry in building electrochemical and catalytic reactors, where exothermic liquid‐solid diffusion‐controlled reactions take place, is highlighted. The present geometry offers the advantage that the outer surface acts as a turbulence promoter while the inner surface acts as a heat exchanger.     

Conceptual design and CFD simulation of a novel metal-based monolith reactor with enhanced mass transfer

This paper introduces a novel structured metallic catalyst that improves mass transfer performance of a monolith reactor for highly exothermic gas–solid reactions. The monolith channels are designed to have metallic substrates that consist of two layers with one of the layers being the metallic support and another layer being a foam metal annular that is tightly deposited onto the support surface by some means. Parametrical studies based on a 2D monolith reactor model showed that the present design yields an enhanced mass transfer between the bulk fluid and the catalyst layer due to a decrease in external film resistance, and an enhanced mass transfer within the solid phase mainly due to the viscous flow effect within the porous catalyst layer.     

Multistage rotor‐stator spinning disc reactor

The scale up of a rotor‐stator spinning disc reactor by stacking single stage rotor‐stator units in series is demonstrated. The gas‐liquid mass transfer per stage is equal to the mass transfer in a single stage spinning disc reactor. The pressure drop per stage increases with increasing rotational disc speed and liquid flow rate. The pressure drop is more than a factor 2 higher for gas‐liquid flow than for liquid flow only, and is up to 0.64 bar at 459 rad s^?1. The high mass and heat transfer coefficients in the (multistage) rotor‐stator spinning disc reactor make it especially suitable for reactions with dangerous reactants, highly exothermic reactions and reactions where selectivity issues can be solved by high mass transfer rates. Additionally, the multistage rotor‐stator spinning disc reactor mimics plug flow behavior, which is beneficial for most processes. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

Effect of Ethylene Glycol on the CO2/Water Gas‐Liquid Mass Transfer Process

The effect caused by the presence of ethylene glycol on the gas‐liquid mass transfer velocity of CO₂ in a aqueous phase has been studied. In this study two different gas‐liquid contactors have been used, a bubbling stirred reactor and a flat surface stirred vessel. The first contactor, gas phase, was introduced using a porous bubbling plate. The influence of operational variables, stirring rate, gas flow rate and ethylene glycol concentration were studied. The experiments were carried out at 298.15 K using a semicontinuous regime. The final aim was to obtain empirical equations that allow the calculation of the mass transfer velocity for this system a priori.     

Impinging zone reactor and its mathematical model for ozonation of waste water

The impinging zone reactor combines the high shear associated with gas‐liquid co‐injection and the impingement of two jet streams to bring about high intensity mixing in a power efficient manner. The reactor has been field tested and proven to be effective and economical for ozonation of wastewater to reduce COD (Chemical Oxygen Demand) and color. A reactor mathematical model has been developed based on fundamental principles where ozone self‐decomposition in water and mass transfer enhancement due to fast reactions are explicitly considered. The model is especially useful for reactor scale‐up design and optimization.     

Volumetric Mass Transfer Coefficient of Oxygen in An Internal Loop Airlift Reactor with a Convergence‐Divergence Draft Tube

Experimental measurements of hydrodynamics and the volumetric mass transfer coefficient of oxygen (VMTCO) in an internal loop airlift reactor with different types of draft tubes are reported for the two‐phase systems, air/water and air/carboxyl methyl cellulose (CMC) solution, and a three‐phase system, air/water/resin particle, respectively. The properties of convergence‐divergence draft tubes with three different structural parameters are compared with those of the conventional column draft tube. The results indicate that gas holdups in convergence‐divergence draft tubes are higher than those in conventional draft tubes, the volumetric mass transfer coefficient of oxygen increases with increasing superficial air flow rates. The convergence‐divergence draft tubes all show higher mass transfer capacity than the traditional ones. A 10% higher mass transfer coefficient is observed for the three structural parameters. In the air/CMC system, the volumetric mass transfer coefficient of oxygen decreases with increasing bulk viscosity, while in the three‐phase system VMTCO increases with the resin particle loading. The correlation equation of the volumetric mass transfer coefficient with the operating conditions and structural parameters is established.     

Numerical Simulation of the Solute‐Induced Marangoni Effect with the Semi‐Lagrangian Advection Scheme

The level set method is combined with the concentration transformation method to solve the interphase mass transfer process. However, the artificial diffusion generated in the mass transfer convection term across the interface is inevitable, especially when large shape deformation is encountered at high Reynolds numbers. A semi‐Lagrangian advection scheme is introduced to overcome this disadvantage. The methyl isobutyl ketone (MIBK)‐acetic acid‐water system is adopted to study the unsteady mass transport process accompanied with the Marangoni effect of a single deformable drop ascending in the infinite continuous phase. The predicted overall mass transfer coefficients agree with experimental data very well. The configuration of Marangoni convection is revealed and its effect on the interphase mass transfer process is investigated.     

Study of Hydrodynamics,Mixing and Gas‐Liquid Mass Transfer in a Split‐Rectangular Airlift Reactor

Global hydrodynamic characteristics, liquid mixing and gas‐liquid mass transfer for a 63 L split‐rectangular airlift reactor were studied. Correlations for gas holdup and overall liquid circulation velocity were derived for the air‐water system as a function of the specific power input; these were compared to data and correlations for reactor volumes between 4.7 L and 4600 L. A partial recirculation of small bubbles in the riser was observed when U_gr > 0.03 m/s, which was attributed to the use of a single‐orifice nozzle as the gas phase distributor. The dimensionless mixing time and the overall axial dispersion coefficient were nearly constant for the range of gas flow rates studied. However, values of K_L/d_B were greater than those reported in previous studies and this is caused by the partial recirculation of the gas phase in the riser. While scale effects remain slight, the use of a gas distributor favouring this partial recirculation seems adequate for mass transfer in split‐rectangular airlift reactors.