Scale‐up und detaillierte Prozessanalyse eines Membranreaktors am Beispiel einer heterogen katalysierten Veresterung

The combination between reaction and pervaporation has been investigated using the example of a heterogeneous catalysed esterification reaction. The process model parameters have been determined based on experimental investigations and a scale‐up has been performed to the pilot scale. A detailed process analysis leads to optimal operating as well as structural variables and two separation sequences have been suggested.     

Photochemical Production of Vitamin D2, Scale‐up and Optimization

An effective low cost method for the photochemical production of vitamin D₂ has been studied, including a 200 L batch photoreactor and a continuous reactor. Following optimization of the irradiation time (550 min), initial concentration of ergosterol (1.4 mg/mL) and the number of lamps employed (16) for the batch reactor, the conversion of ergosterol is ca. 50 %, and the selectivity yield of pre‐vitamin D₂ is ca. 84 %. The corresponding data for the continuous reactor are 73 % and 62 %, respectively.     

Scale‐up of Mini‐Plant Extractors on Energy Dissipation‐Based Population Balances

The new scale‐up concept for extraction columns relies on three identities being kept idem, as is the total specific flow rate, energy dissipation, and mean droplet residence time in a compartment. The droplet population balance‐based model allows maintaining hydrodynamic similarity in different geometries, as is in a mini‐ or a pilot plant. This leads to similar breakage and coalescence probabilities giving comparable droplet size distributions, thus mass transfer area and extraction efficiency. A new breakage frequency term has been developed relying on the energy dissipation rate and is thus independent from geometric constraints. The traditional scale‐up rules are based either on a constant tip velocity (≈ N) or on a constant energy input (≈ N³), whereas here it follows a constant energy dissipation (≈ N²). A step‐by‐step approach to the new procedure proved by case samples is given. Data from literature pilot experiments could be verified by computer simulations, without using adaptable parameters. All parameters in the correlations where derived in a lab‐scale apparatus and the coalescence parameters were obtained in the mini‐plant experiments. Derivation between simulated and experimental pilot data for stage numbers was less than 14 %, operating parameters (rotational speed N, throughput) were underestimated by 4 % leading to a slightly smaller HETS (Height Equivalent of Transfer Stages) value as measured, affecting the column height with less than 1 %.     

Strategy for a Scale‐up Correlation in a Dissolved Air Flotation Chamber

Beginning with a laboratory‐scale physical model, a scale‐up correlation for a pilot unit project was determined based on the analysis of dynamic similarity correlations involving the predominant phenomena of a dissolved air flotation (DAF) chamber. The implantation costs of pilot units require special strategies due to the lack of correlations of this type, as novel flotation methods have been considered strictly from an economic standpoint. With the aid of computational fluid dynamics and videos of microbubble and floc flow, inertia and gravity were identified as the predominant phenomena in a DAF chamber. The strategy described herein is simple and reduces the likelihood of future risks in scale‐up investments.     

Scale‐up and Spouting of Two‐Dimensional Beds

The objective of this paper is to present an analysis on the scale‐up procedure of two‐dimensional spouted beds. The task was carried out with three different beds measuring 0.15, 0.30 and 0.80 in width. The conditions of scale‐up were studied through geometrical similitude analysis. Some parameters of scale were adimensionalised, tested and validated in order to propose relationships capable of predicting values of dependent properties. Those relationships should be followed in a prototype of an equipment of industrial scale. The study permitted the development of correlations to predict values of maximum pressure drop, minimum spout velocity and maximum height of spouting.     

Scale‐up of adsorptive styrene drying

This work is focused on the analysis of the scale‐up process of styrene drying by adsorption onto activated alumina as a necessary step in the manufacture of styrene–butadiene rubber. In a previous work, the mathematical model was developed and the design parameters were estimated from the fitting of the model to experimental results obtained in a laboratory set‐up. The obtained model and parameters have been used to simulate the behaviour of a pilot plant that contains up to 56 times more sorbent stating their validity after comparison with experimental results. Finally, the behaviour of an industrial plant presently at work, was also satisfactorily described. The ability of the model to simulate experimental results obtained on three different scales checks its adequacy for process design and optimization. © 2002 Society of Chemical Industry     

Heterogen katalysierte Hydrierung von Kohlendioxid zu Methan unter erhöhten Drücken

Ni‐ and Ru‐containing supported catalysts were prepared and used for the CO₂ hydrogenation to methane (Sabatier reaction) in the gas phase. Tests on the effect of the reaction temperature and pressure were in the focus. ZrO₂ and γ‐Al₂O₃ were used as suitable catalyst supports. CO₂ and H₂ conversions of 70 – 80 % and selectivity to methane of > 99 % were reached. TiO₂ and SiO₂ based catalysts exclusively lead to CO and seem to be not suited for this reaction. The investigations on the pressure effect impressively demonstrated the influence on the chemical equilibrium. CO₂ and H₂ can be nearly completely converted with > 99.9 % selectivity to methane over Ru/ZrO₂.     

Zeitverhalten der isothermen Reaktivdestillation beim thermischen Cracken und Desoxygenieren von Rapsöl

Thermal cracking of rapeseed oil under isothermal reactive distillation conditions allows the production of alternative liquid fuels. Temporal changes of the sump phase and the oil condensate show an increased higher heating value due to deoxygenation. The sump phase also shows an increasing thermal stability, accompanied by polymerization and aromatization. This is derived from a changing iodine value, H/C ratio as well as viscosity. The deoxygenation of the oil condensate is confirmed by a decreasing acid value and the reduction of detected carboxylic acids.     

Mathematical Modeling and Methodic Scale‐up for Efficient Filter Apparatus Development

In many filtration applications, process parameters vary considerably due to differing boundary conditions. To develop a new filter apparatus, consequently the whole bandwidth of possible scenarios has to be considered for a fully functional real‐scale design. In order to reduce experimental efforts, analytical and numerical methods can be useful. For dimensioning of a new design apparatus for lube oil filtration in large diesel engines, a methodic approach could be developed with a mathematical model for the characteristics of the clogging process. With this method, all possible operative settings can be easily simulated and the experimental effort is considerably reduced.     

Modellierung und Simulation von Filtrations‐, Regenerations‐ und Umlagerungseffekten in Gasfiltersystemen am Beispiel eines Dieselruß‐Partikelfilters

The drastic tightening of regulations regarding emission limits of motor vehicles demands for an efficient exhaust gas treatment of diesel motor engines. One potential concept is an integrated diesel soot filter within the exhaust gas system. Basic requirement for a safe filter system operation is a fundamental comprehension of all involved individual processes. In this paper an experimentally validated CFD‐model describing the life cycle of a diesel root filter is presented. Its results can be used to fully exploit the potential of such filter systems and provide a basis for a variety of applications in the field of gas filtration.     

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.     

Predicting Power for a Scaled‐up Non‐Newtonian Biomass Slurry

High‐solids biomass slurries exhibit non‐Newtonian behavior with a yield stress and require high power input for mixing. The goals were to determine the effect of scale and geometry on power number P₀, and estimate the power for mixing a pretreated biomass slurry in a 3.8 million L hydrolysis reactor of conventional design. A lab‐scale computational fluid dynamics model was validated against experimental data and then scaled up. A pitched‐blade turbine and A310 hydrofoil were tested for various geometric arrangements. Flow was transitional; laminar and turbulence models resulted in equivalent P₀ which increased with scale. The ratio of impeller diameter to tank diameter affected P₀ for both impellers, but impeller clearance to tank diameter affected P₀ only for the A310. At least 2 MW is required to operate at this scale.