MASS TRANSFER INTO LAMINAR GAS STREAMS IN WETTED-WALL COLUMNS WITH COUNTERCURRENT GAS-LIQUID FLOW

The effect of the gas and liquid flow rates on the mass transfer rate in laminar gas streams in wetted-wall columns with countercurrent gas-liquid flow was studied. An approximate analytical solution was obtained for the average gas-phase Sherwood number as a function of the gas-phase Graetz number and the dimensionless interfacial gas velocity. Experiments were carried out on the absorption of ammonia into aqueous sulfuric acid solution and of methanol vapor into water, using two columns of different lengths. The agreement between the experimental and the predicted effects of both gas and liquid flow rates on the gas-phase mass transfer rate was found to be fairly good.     

MASS TRANSFER INTO LAMINAR GAS STREAMS IN WETTED-WALL COLUMNS WITH COUNTERCURRENT GAS-LIQUID FLOW

The effect of the gas and liquid flow rates on the mass transfer rate in laminar gas streams in wetted-wall columns with countercurrent gas-liquid flow was studied. An approximate analytical solution was obtained for the average gas-phase Sherwood number as a function of the gas-phase Graetz number and the dimensionless interfacial gas velocity. Experiments were carried out on the absorption of ammonia into aqueous sulfuric acid solution and of methanol vapor into water, using two columns of different lengths. The agreement between the experimental and the predicted effects of both gas and liquid flow rates on the gas-phase mass transfer rate was found to be fairly good.     

Pressure Drop and Flooding Limit in Spinning Cone Columns

This work investigated the change in pressure drop in spinning cone columns with varying liquid and gas flow rates, and the physical processes that underlie this behavior were studied. The flow regimes include pre-loading, loading, and flooding. The boundaries between these regimes can be specified in terms of a dynamic (force-based) Froude number (Fr_LG), reflecting the inertial-gravity force balance of the liquid-gas mixture. Loading occurs above a Fr_LG value of 0.1 and flooding above Fr_LG of unity. The criteria of Fr_LG = 0.1 for loading and Fr_LG of unity for flooding agree with the experimental data and with the earlier correlation of the data in an SLE-type chart form. Using a rotation- and gravity-related normalization of variables, the normalized increase in the pressure drop due to liquid (ΔP_L) is transformed into a function of the kinematic (velocity-based) Froude number Fr_G, where Fr_G = Q_G/A√(gP_C), and Q_G is the volumetric gas flow rate, A is an appropriately defined area, g is the acceleration due to gravity, and P_C is the cone pitch. Pressure-drop data for a small spinning cone column have been analyzed, where this equipment has a diameter of 0.148 m, a range of rotational speeds from 500 to 1500 rpm, and gas and liquid flow rates up to 300 L min^-1 and 1.5 L min^-1, respectively. For this equipment, ΔP_L = 3.26 Fr_G² in the pre-loading regime and ΔP_L = 0.093 Fr_G⁶ in the loading regime, with these correlations explaining 73% and 79%, respectively, of the variation in the experimental data. Based on these approximations, dimensional diagrams of the liquid load regimes have been constructed that may be used to guide the design and operation of different-sized columns.     

Inline Measurement of the Residence Time Distribution in High-Pressure Extraction Columns

Axial backmixing lowers the efficiency of packed countercurrent high-pressure extraction columns. To quantify backmixing, a method of measuring the residence time distribution and calculating the axial dispersion coefficient in high-pressure extraction columns is introduced. Using a design of experiments, the effect of supercritical and liquid mass flow rates as well as the pressure at a constant temperature on the mean residence time and the axial dispersion coefficient are evaluated for the system water/supercritical CO₂. The experimental data is correlated to the Reynolds and Schmidt number.     

Experimental and numerical investigation of liquid circulation induced by a bubble plume in a baffled tank

Bubble induced liquid circulation is important in applications such as bubble columns and air-lift reactors. In this work, we describe an experimental and numerical investigation of liquid circulation induced by a bubble plume in a tank partitioned by a baffle. The baffle divides the tank into two compartments. Liquid can flow from one compartment to the other through openings at the top and the bottom of the baffle. Gas (air) was injected in the riser section in the form of bubbles at one corner of the tank. The temporal and spatial variation of velocity field in the liquid as a function of the gas flow rate was measured using particle image velocimetry (PIV). At a constant gas flow rate, the liquid flow field is unsteady due to the interaction with the bubbles. The time scales associated with the velocity-time series and the bubble plume thickness variation were calculated. The time averaged-velocity field was used to quantify the variation of the liquid circulation rate with gas flow rate. The turbulence in the liquid was measured in terms of turbulent intensities. These were calculated from the experimental data and were observed to be less than 3 cm/s. A 2-d Euler-Euler two-fluid model with buoyancy and drag as the interaction terms was used to simulate the flow. The parameters chosen for the simulations were selected from literature. It is shown that inclusion of turbulence model such as k-ε is necessary to capture the overall flow behavior. Good agreement was observed between experimentally obtained velocity profiles and the recirculation rates with the simulation results.     

Axial dispersion in a rectangular bubble column

This paper presents the results of an experimental study on the gas holdup and the liquid phase axial dispersion coefficient in a narrow packed and unpacked rectangular bubble column. In both cases the gas and liquid flow rates were varied and the data were obtained by employing standard tracer technique. The gas holdup and the axial dispersion coefficient for both the packed and unpacked columns were found to be dependent on the gas and liquid flow rates. For given gas and liquid velocities and a given packing size in the case of the packed column, the rectangular column gave significantly higher dispersion coefficients than a cylindrical column of the equivalent cross sectional area. This result agrees very well with the one predicted by the velocity distribution model. The correlations for the Peclet number, the axial dispersion coefficient, and the fluid holdup for both the unpacked and packed bubble columns are presented.     

Investigation by laser Doppler velocimetry of the effects of liquid flow rates and feed positions on the flow patterns induced in a stirred tank by an axial-flow impeller

The flow patterns established in a continuously-fed stirred tank, equipped with a Mixel TT axial-flow impeller, have been investigated by laser Doppler velocimetry, for a high and a low value of mean residence time—mixing time ratio. The pseudo-two-dimensional axial-radial-velocity vector plots, as well as the spatial distributions of the tangential velocity component and the velocity profiles around the impeller, show that the interaction between the incoming liquid and the liquid entrained by the agitator rotation cause the flow pattern in the vessel to become strongly three-dimensional, especially in the region between the plane, where the feeding tube lies, and the 180°-downstream plane. The increase in the liquid flow rate and the location of the feed entry both affect the flow pattern, with the latter having a more pronounced effect. The overall process, in this mode of operation, depends upon the appropriate configuration and choice of parameters: for conditions corresponding to high liquid flow rates, the flow patterns indicate the possibility of short-circuiting, when the liquid is fed into the stream being drawn by the agitator and when the outlet is located at the bottom of the vessel.     

Heat transfer in co-current vertical two-phase flow

Heat transfer in co-current two-phase upflow and downflow of air–water has been investigated in a 25.8 mm electrically heated vertical pipe at 172.3 kPa for water mass velocities of 54 to 172 kg/m²s and gas flow rates of 0 to 1.322 × 10⁻² m³/s. It was found that although the injection of air in the liquid flow increased the two-phase heat transfer coefficients significantly for both systems, upflow coefficients were generally higher than those for downflow for the same liquid flow rate. This could have important implications in the design of some chemical reactors and heat engineering processes. Changes in heat transfer rates were found to occur at the flow pattern transition boundaries. Two-phase heat transfer coefficients were well correlated by an expression based on dimensional analysis for both upflow and downflow.     

Induced pulsing in trickle beds—characteristics and attenuation of pulses

Gas/liquid down-flow in packed beds is studied, under periodic liquid feeding (at sufficiently high frequencies to be classified as “fast” mode of pulsing), in a range of mean liquid and gas flow rates within the steady “trickling flow regime”. The aim is to identify periodic feeding conditions resulting in improved fluid-mechanical characteristics (e.g. uniform fluids distribution) and possibly enhanced transport rates in this flow regime, which is common in industrial processes. From instantaneous, cross-sectionally averaged holdup measurements, at various locations along the packed bed, quantitative information is obtained on the axial propagation and attenuation of induced pulses. A phenomenological treatment of the pulse decay process facilitates data interpretation and leads to the determination of a characteristic attenuation factor for the various conditions tested. Key parameters of the process studied include, in addition to dynamic holdup, pressure drop, pulse celerity and intensity, as a function of fluid feed rates (G,L) and liquid cyclic frequency. Under the conditions of these tests, and for fixed mean rates G,L, the time averaged holdup and the pulse celerity are practically constant along the bed; furthermore, these quantities as well as the pressure drop do not seem to be affected by the imposed cyclic liquid feeding frequency. An expression to tentatively correlate pulse celerity data is recommended.The computed attenuation factors indicate that there is a rather narrow band of mean gas and liquid rates (along the so-called “pseudo-transition” boundary to pulsing flow) where pulse decay is at a minimum. Based on these results as well as on pulse intensity vs. bed length data, recommendations are made on preferred conditions for induced pulsing (from the fluid-mechanical standpoint) which would maximize expected benefits.     

Sensor‐based flow pattern detection—gas–liquid–liquid upflow through a vertical pipe

Flow distribution during gas–liquid–liquid upflow through a vertical pipe is investigated. The optical probe technique has been adopted for an objective identification of flow patterns. The probability density function (PDF) analysis of the probe signals has been used to identify the range of existence of the different patterns. Dispersed and slug flow have been identified from the nature of the PDF, which is bimodal for slug flow and unimodal for dispersed flow. The water continuous, oil continuous, and emulsion type flow distributions are distinguished on the basis of the PDF moments. The method is particularly useful at high flow rates where visualization techniques fail. Based on this, a flow pattern detection algorithm has been presented. Two different representations of flow pattern maps have been suggested for gas–liquid–liquid three phase flow. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3362–3375, 2014     

Exclusion of gas sparger influence on mass transfer in bubble columns

Gas phase CO₂ concentration profiles were measured in two sizes of bubble columns with different gas spargers and with the liquid phase (tap water) entrance or exit (cocurrent or countercurrent flow) at a certain height above the gas distributor. The region of high turbulence intensity near the sparger was locally separated from the region of high mass transfer rates in such columns. A modified back flow cell model was applied to describe the experimental data. The k_L-values obtained from fitting the profiles agreed for both columns and, in addition, did not differ for cocurrent and countercurrent flow. This is in remarkable contrast to previous findings(10,11). The large influence of the gas sparger on the k_L-values even in tall bubble columns was thus demonstrated. It is thought that this may probably be one of the reasons why correlations for prediction of k_L differ so significantly.     

Effect of Structural Parameters on Drop Size Distribution in Pulsed Packed Columns

The effect of packing type on drop size distribution in pulsed packed columns was investigated by means of different columns and three packing types with three liquid systems including n‐butyl acetate, toluene, and kerosene with water. These liquid systems cover a wide range of interfacial tensions. Also the influence of operating variables in terms of pulse intensity and volumetric flow rates of dispersed and continuous phases was examined. Pulse intensity, interfacial tension, and packing shape were found as the main important factors for drop size distribution while volumetric flow rates had no significant effect. Correlations are presented to predict drop distribution and mean drop size in pulsed packed columns.     

Calculation of flow fields in two and three-phase bubble columns considering mass transfer

The dimension of bubble column reactors is often based on empirical correlations. Very popular is the axial dispersion model. However, the applicability of these models is limited to the experimental conditions for which the dispersion coefficients are measured, because backmixing depends strongly on the columns dimension and the flow regime. This paper presents a numerical method for the calculation of the three-dimensional flow fields in bubble columns based on a multi-fluid model. Therefore, the local bubble size distribution is considered by a transport equation for the mean bubble volume, which is obtained from the population balance equation. For comparison with experimental results, the axial dispersion coefficients in the liquid and gas phase are calculated from the instationary, three-dimensional concentration fields of a tracer. The model is then extended to include mass transfer between the gas and liquid phase. Increasing mass transfer rates significantly influence the flow pattern. For several applications, a dispersed solid phase is added. For the calculation of three-phase gas-liquid-solid flow, the solid phase is considered numerically by an additional Eulerian phase.     

Impact of gravity on the bubble‐to‐pulse transition in packed beds

A model based on two‐phase volume‐averaged equations of motion is proposed to examine the gravity dependence of the bubble‐to‐pulse transition in gas‐liquid cocurrent down‐flow through packed beds. As input, the model uses experimental correlations for the frictional pressure drop under both normal gravity conditions and in the limit of vanishing gravity, as well as correlations for the liquid‐gas interfacial area per unit volume of bed in normal gravity. In accordance with experimental observations, the model shows that, for a given liquid flow, the transition to the pulse regime occurs at lower gas‐flow rates as the gravity level or the Bond number is decreased. Predicted transition boundaries agree reasonably well with observations under both reduced and normal gravity. The model also predicts a decrease in frictional pressure drop and an increase in total liquid holdup with decreasing gravity levels. © 2013 American Institute of Chemical Engineers AIChE J 60: 778–793, 2014     

Paste extrusion through non-axisymmetric geometries: Insights gained by application of a liquid phase drainage criterion

An experimental investigation has been conducted into the flow of a talc-based paste through various combinations of axisymmetric and non-axisymmetric ram extruder geometries. The paste flow pattern was found to be highly rate dependent for one non-axisymmetric case. The flows were modelled using the Benbow-Bridgwater approach, but this was incapable of predicting the observed flow patterns and under-predicted the extrusion pressure at low flow rates. Evidence suggested that significant liquid phase migration was occurring at low flow rates, with associated dewatering of paste in the barrel. The situation where significant liquid phase migration occurs is comparable to a drained experiment in soil mechanics. The simple, but little known, drainage criterion of Wroth and Houlsby was used to estimate the flow rates associated with drained and undrained conditions. The criterion successfully predicted the flow rate at which transition of the flow pattern was observed. Comparable experiments using a modelling clay, undrained over all flow rates, showed no transition in flow pattern. Furthermore, the drainage criterion successfully predicted the drainage state for three of four other paste flow data sets taken from the literature covering a variety of materials and geometries. It is concluded that: (i) liquid phase migration can be a significant feature of paste extrusion which can dramatically alter the flow patterns in non-axisymmetric extruders, and (ii) that the Wroth and Houlsby's criterion can successfully predict the drainage state of a process but is limited by the estimation of the coefficient of permeability.     

Flooding in inclined pipes — Effect of entrance section

Flooding in countercurrent flow of air and water in inclined tubes has been investigated. Data on flooding inception in the whole range of inclinations have been collected and predictive models for calculating the flooding conditions as a function of the flow rates and pipe inclination were proposed. Special attention is placed on the effect of the liquid injection mode. It has been shown that the porous injection system causes a local disturbance and enhances flooding at relatively shallow inclinations and high liquid flow rates.     

Two-phase flow regimes in microchannels

Capillary hydrodynamics has three considerable distinctions from macrosystems: first, there is an increase in the ratio of the surface area of the phases to the volume that they occupy; second, a flow is characterized by small Reynolds numbers at which viscous forces predominate over inertial forces; and third, the microroughness and wettability of the wall of the channel exert a considerable influence on the flow pattern. In view of these differences, the correlations used for tubes with a larger diameter cannot be used to calculate the boundaries of the transitions between different flow regimes in microchannels. In the present review, an analysis of published data on a gas-liquid two-phase flow in capillaries of various shapes is given, which makes it possible to systematize the collected body of information. The specific features of the geometry of a mixer and an inlet section, the hydraulic diameter of a capillary, and the surface tension of a liquid exert the strongest influence on the position of the boundaries of two-phase flow regimes. Under conditions of the constant geometry of the mixer, the best agreement in the position of the boundaries of the transitions between different hydrodynamic regimes in capillaries is observed during the construction of maps of the regimes with the use of the Weber numbers for a gas and a liquid as coordinate axes.     

Modelling of mass transfer in plate columns with dual flow

Dual flow operation of plate columns has been modelled by the use of a liquid bypass stream. Both the liquid flowrate entering a plate and the liquid composition on the plate show cyclic variations from plate to plate. The overall column efficiency is significantly reduced and varies with the number of plates. The scaleup rules for dual flow columns based on column diameter have been reported in the literature while the scaleup rules based on column height as described in this paper, are more complicated than the constant plate efficiency rules that apply under the simplest case of conventional flow operation.     

Packed extraction columns: A review of correlations for maximum throughput

A considerable amount of experimental data on maximum flow rates of countercurrently flowing liquid phases in packed columns has been published and a number of correlations for flooding velocities have been proposed. In the present paper various correlations are tested, using the same set of experimental results selected according to plausible criteria. The results of the test are presented in a consistent manner. Reasons why the result arrived at in this review differ from the recommendation given in Reference 10 are discussed.