Chemical hydrodynamics of a downward microbubble flow for intensification of gas‐fed bioreactors

Bioreactors are of interest for value‐upgrading of stranded or waste industrial gases. Reactor intensification requires development of low cost bioreactors with fast gas–liquid mass transfer rate. Here we assess published reactor technology in comparison with a novel downward bubble flow created by a micro‐jet array. Compared to known technology, the advanced design achieves higher volumetric gas transfer efficiency (k_La per power density) and can operate at higher k_La. We measure the effect of four reactor heights (height‐to‐diameter ratios of 12, 9, 6, and 3) on the gas transfer coefficient k_L, total interfacial area a, liquid residence time distribution, energy consumption, and turbulent hydrodynamics. Leading models for predicting k_L and a are appraised with experimental data. The results show k_L is governed by “entrance effects” due to Higbie penetration dominate at short distances below the micro‐jet array, while turbulence dominates at intermediate distances, and finally terminal rise velocity dominates at large distances. © 2017 American Institute of Chemical Engineers AIChE J, 64: 1399–1411, 2018     

Macroscopic analysis of polarization characteristics of gas-diffusion electrodes in contact with liquid electrolytes: Part I: First order reactions

In this paper principles of gas-liquid chemical reaction engineering are applied to analyse the current-potential characteristics of gas-diffusion electrodes (GDE) in contact with liquid electrolytes. A macroscopic electrode model is formulated which accounts for mass transfer in the external diffusion films, in the gas layer and in the flooded layer. The set of model equations accounts for material balances, mass transport kinetics and Butler-Volmer polarization kinetics. Several dimensionless parameter groups are introduced which allow a compact reformulation of the proposed model. For first order reactions its solution can be derived analytically. The introduced parameter groups allow a classification of the different operating modes of a GDE, that is, slow reaction, fast reaction and instantaneous reaction.     

Hydrodynamics and mass transfer of gas–liquid flow in a falling film microreactor

In this article, flow pattern of liquid film and flooding phenomena of a falling film microreactor (FFMR) were investigated using high‐speed CCD camera. Three flow regimes were identified as “corner rivulet flow,” “falling film flow with dry patches,” and “complete falling film flow” when liquid flow rate increased gradually. Besides liquid film flow in microchannels, a flooding presented as the flow of liquid along the side wall of gas chamber in FFMR was found at high liquid flow rate. Moreover, the flooding could be initiated at lower flow rate with the reduction of the depth of the gas chamber. CO₂ absorption was then investigated under the complete falling flow regime in FFMR, where the effects of liquid viscosity and surface tension on mass transfer were demonstrated. The experimental results indicate that k_L is in the range of 5.83 to 13.4 × 10^?5 m s^?1 and an empirical correlation was proposed to predict k_L in FFMR. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

A multi‐scale theoretical model for gas–Liquid interface mass transfer based on the wide spectrum eddy contact concept

On the basis of the wide spectrum eddy contact concept and the isotropic turbulence theory, a multi‐scale theoretical model for the prediction of liquid‐side mass transfer coefficient in gas–liquid system was developed. The model was derived from an unsteady‐state convection and diffusion equation and considered the contributions of eddies with different sizes to the overall mass transfer coefficient. The proper contact time distribution at the surface is need to be determined to obtain satisfactory results with this model. Moreover, a simplified model was also proposed based on the assumption of steady‐state mass transfer mechanism for single eddy. The results predicted by this model showed a very good agreement with the available experimental data in a comparatively wide range of turbulence intensities. © 2010 American Institute of Chemical Engineers AIChE J, 2011     

Mass transfer in horizontal flow channels with thermal gradients

Mass transfer to a wall of a horizontal rectangular channel reactor was investigated by the limiting current technique for Reynolds numbers ranging from 200 to 32000. Overall mass transfer coefficients at various mass transfer surface angles were obtained while the reactor was operated under isothermal and non-isothermal conditions. Dimensionless correlations were developed for isothermal flows from 25 to 55°C and for non-isothermal flows with applied temperature differences up to 30°C. In the laminar flow range natural convection dominated, but under turbulent conditions combined natural and forced convection prevailed. Mass transfer was approximately doubled under optimum selection of channel surface rotation, temperature gradient and flow rate.     

Enhancement of mass transfer in flow channels under thermal gradients

Overall mass transfer coefficients, at the solid liquid interface in a rectangular cross-section flow reactor, were obtained using the limiting current technique. Empirical correlations were developed for single-phase flow for a full range of surface configurations, for laminar and turbulent flow regimes, and for isothermal and non-isothermal conditions. Isothermal mass transfer was almost doubled by the selection of the reactor slope and surface configuration. Imposition of up to a 30°C difference at the interface, enhanced mass transfer approximately four times, over the isothermal case. Mathematical simulation for mass transfer in flow reactors, is shown to agree within 15% of experimental values found in the literature and for the experiments reported here.     

Kinetics and mass transfer in hydroformylation—bulk or film reaction?

The kinetics of a gas–liquid reaction, alkene hydroformylation was studied in the presence of a homogeneous catalyst in a pressurised laboratory‐scale semibatch reactor. Hydroformylation of propene to isobutyraldehyde and n‐butyraldehyde was carried out at 70–115°C and 1–15 bar pressure in 2,2,4‐trimethyl‐1,3‐pentanediol monoisobutyrate solvent with rhodium catalyst using the ligands cyclohexyl diphenylphosphine. In order to evaluate the influence of mass transfer, experiments were made using varied stirring rate from 100 to 1000 rpm at 100°C and 10 MPa syngas pressure. Only at higher stirrings rates, the reaction took place in the kinetic regime. A reactor model was developed comprising both complex kinetics and liquid‐phase mass transfer. The model was based on the theory of reactive films. The model is able to predict under which circumstances the hydroformylation process is affected by liquid‐phase diffusion of the reactants. Experimental data and model simulations are presented for the hydroformylation of propene in the presence of a homogeneous rhodium catalyst.     

Liquid‐bridge flow in the channel of helical string and its application to gas–liquid contacting process

To solve the problems of the traditional packings, such as high pressure drop, mal‐distribution and short liquid residence time, a helical flow structured packings was proposed. Two different flow patterns, liquid‐bridge flow and liquid‐drop flow were identified when the width of the channel of the helical string was adjusted. Moreover, the characteristics of the helical liquid‐bridge flow including maximum liquid loading, mean thickness of liquid film, mean residence time and effective specific surface area, were examined. And the separation efficiency was studied by the lab‐scale distillation column. In comparison, the effective specific surface area of the helical flow type packings is almost as large as the traditional B1‐350Y structured packings, but with thinner liquid film, longer liquid residence time and finally higher separation efficiency. © 2018 American Institute of Chemical Engineers AIChE J, 64: 3360–3368, 2018     

Mass transfer and deodorization efficiency in a countercurrent spray tower for low superficial gas velocities

The aim of this study was to characterize mass transfer and deodorization efficiency in a countercurrent spray tower for low superficial gas velocities. The influence of operating parameters (U_G = 0.005 to 0.025 m s^?1, U_L = 6.1 × 10^?5 to 2.4 × 10^?4 m s^?1) on the liquid retention (ε_L), the drop diameter (d_g), the interfacial area (a) and the overall liquid and gas phase mass transfer coefficients (K_La, K_Ga) were estimated. The spray efficiency of some malodorous compounds was also estimated. A negative influence of the superficial gas velocity was demonstrated, during the spraying of water or chemical neutralizing scrubbing solutions. There was also an increase with the liquid flow rate. Abatements obtained were very good with respect to ammonia (>90%), and acceptable for the other compounds.     

几何结构对滤压式电解槽内部传质的影响

Effect of configuration （structure of electrode, interelectrode gap, positions of inlet and outlet, volume of the cell and additional nets） on mass transfer characteristic of a filter-press type electrochemical cell has been studied. The mass transfer coefficients on the electrodes were obtained by using the well-known technique based on the determination of limiting diffusion current. It is found that mass transfer coefficients with mesh electrode are greater than that of with plate electrode. Mass transfer coefficient is decreased with interelectrode gap. While interelectrode gap achieved a certain value （7 ram）, mass transfer coefficient is steady, no more declining. Mass transfer characteristic for different positions of inlet and outlet are different and dimensionless number groups correlated equations are obtained by experiment. Mass transfer characteristic is the best when inlet located on the top and outlet on the bottom of the cell respectively. While magnified the volume of the cell to eight times, mass transfer characteristic changes little. Mass transfer characteristic without nets is lower than that of with additional nets in the exit region, but higher than that of with additional nets in the entry region.     

Influence of top‐section design and draft‐tube height on the performance of airlift bioreactors containing water‐in‐oil microemulsion

The mixing and mass transfer characteristics of draft‐tube airlift bioreactors (DTAB) for a water‐in‐kerosene microemulsion, as a cold model of petroleum biodesulfurization, were studied. Incomplete gas disengagement at the top‐section of the DTAB and hence high gas recirculation were obtained with the microemulsion system for all the top‐section configurations employed in the present study especially at the high airflow rates. The ratio (S) of the volumes of the riser and the downcomer to the top‐section together with the gas disengagement abilities of the gas separator were both found to affect the mixing performance of the DTAB employed for the microemulsion system. Increase in the draft‐tube height resulted in significant increase in the mixing time (t_m) and a slight increase in the overall volumetric oxygen transfer coefficient (k_La). Increase in the diameter of the top‐section and the height of the liquid above the draft‐tube led to a decrease in k_La, the latter effect being less prominent. New correlations were developed that predicted the mixing time and oxygen transfer coefficients obtained in the present work with reasonable accuracy. Copyright © 2004 Society of Chemical Industry     

Experimental study of O2 diffusion coefficient measurement at a planar gas–liquid interface by planar laser‐induced fluorescence with inhibition

A new method for determining the molecular diffusivity of oxygen in liquids is described. The technique was applied through a flat air–liquid interface in a Hele‐Shaw cell (5 × 5 × 0.2 cm³) and was based on planar laser‐induced fluorescence (PLIF) with inhibition. A ruthenium complex (C₇₂H₄₈N₈O₆Ru) was used as the fluorescent dye sensitive to oxygen. A mathematical analysis was developed to determine the molecular diffusivity of oxygen simply by localizing the gas diffusion front. The specificity of this mathematical analysis is that it does not require the properties of the fluids (such as the saturation concentration) to be considered, which is especially relevant for complex media that are sometimes difficult to characterize properly. This technique was applied to three different fluids (viscosities ranging from 1 to 2.4 mPa·s) corresponding to binary diffusion coefficients ranging from 9.5 × 10^?10 to 2 × 10^?9 m²/s. Experimental data were found with an uncertainty of about 5% and were in good agreement with the literature. Particle image velocimetry and numerical simulations were also carried out to determine the optimal gas flow rate (0.01 L/s) to reach purely diffusive transfer, and the corresponding hydrodynamic profiles of the two phases. © 2012 American Institute of Chemical Engineers AIChE J, 59: 325–333, 2013     

Helical liquid flow on a vertical cylinder and its application to gas absorption

An experimental examination of a novel device for enhancing the gas absorption into an aqueous absorbent flowing down the outer wall of a vertical cylinder was reported. This device utilizes flexible strings tightly wound around the cylinder, taking the form of a multiple helix. The absorbent flows along parallel channels partitioned by the strings, maintaining mutual contact with the surrounding gas for a longer time than it would when it flows down the same cylinder wall in the absence of such strings. Both flow‐observation experiments and absorption experiments using water as the absorbent flowing along a single helical channel and carbon dioxide as the gas to be absorbed were carried out. The effectiveness of the helical‐flow device for promoting the absorption was recognized at water flow rates high enough to induce an oscillatory flow mode accompanied by periodical liquid?gas interface deformation. © 2013 American Institute of Chemical Engineers AIChE J, 59: 3109–3118, 2013     

Bubble shape,gas flow and gas–liquid mass transfer in pulp fibre suspensions

Gas–liquid mass transfer in pulp fibre suspensions in a batch‐operated bubble column is explained by observations of bubble size and shape made in a 2D column. Two pulp fibre suspensions (hardwood and softwood kraft) were studied over a range of suspension mass concentrations and gas flow rates. For a given gas flow rate, bubble size was found to increase as suspension concentration increased, moving from smaller spherical/elliptical bubbles to larger spherical‐capped/dimpled‐elliptical bubbles. At relatively low mass concentrations (C_m = 2–3% for the softwood and C_m ? 7% for the hardwood pulp) distinct bubbles were no longer observed in the suspension. Instead, a network of channels formed through which gas flowed. In the bubble column, the volumetric gas–liquid mass transfer rate, k_La, decreased with increasing suspension concentration. From the 2D studies, this occurred as bubble size and rise velocity increased, which would decrease overall bubble surface area and gas holdup in the column. A minimum in k_La occurred between C_m = 2% and 4% which depended on pulp type and was reached near the mass concentration where the flow channels first formed.     

Effects of surfactants on hydrodynamics and mass transfer in a split‐cylinder airlift reactor

Effects of various concentrations (0–5 ppm) of anionic (sodium dodecyl sulfate, SDS) and non‐ionic (Tween‐80 and Triton X‐405) surfactants on gas hold‐up and gas–liquid mass transfer in a split‐cylinder airlift reactor are reported for air–water. Surfactants were found to strongly enhance gas hold‐up. Non‐ionic surfactants were more effective in enhancing gas hold‐up compared to the anionic surfactant SDS. An enhanced gas hold‐up and a visually reduced bubble size in the presence of surfactants implied an enhanced gas–liquid interfacial area for mass transfer. Nevertheless, the overall gas–liquid volumetric mass transfer coefficient was reduced in the presence of surfactants, suggesting that surfactants greatly reduced the true liquid film mass transfer coefficient and this reduction outweighed the interfacial area enhancing effect. Presence of surfactants did not substantially affect the induced liquid circulation rate in the airlift vessel.     

Gas–liquid mass transfer studies for biomass support materials in a bioreactor

BACKGROUND: Oxygen mass transfer can be described and analyzed by means of the mass transfer coefficient k_La, which is the most important parameter involved in the design and operation of mixing–sparging equipment for bioreactors. In the present study, the effect of biomass support materials on the gas–liquid mass transfer coefficient was studied in a bioreactor under variable process conditions. The biomass support materials used were activated carbon, pumice and loofa sponge. RESULTS: Compared with the case with distilled water only, the presence of the biomass support materials negatively influenced mass transfer. On the other hand, the mass transfer coefficient increased with increased impeller speed, air flow rate and temperature; and decreased with the increase of liquid viscosity and biomass support material concentration for all cases. CONCLUSIONS: Evaluation of the experimental data showed that k_La values were affected by process variables. Besides the major exponential correlations used in the literature, satisfactory linear correlations for the relationship between the k_La and process variables were obtained. Copyright © 2010 Society of Chemical Industry