Numerical investigation of the reactive gas–solid characteristics in biomass fast pyrolysis of conical spouted reactor equipped with draft tube

Biomass fast pyrolysis is a promising technology to produce available char and high-value gas due to its green and sustainable ability. In the current work, the biomass fast pyrolysis in draft tube spouted bed has been numerically investigated via the multiphase particle-in-cell model. In this model, gas turbulence is calculated via large eddy simulation and particles are individually tracked in the Lagrangian manner. This model is successfully validated against experimental data. The particle-scale information of sand and biomass feedstock has been discussed, and the influence of draft tube configuration on the pyrolysis performance has been studied. The results show that the equipment of draft tube prevents gas leakage from spout to annulus, leading to large axial gas flux in the spout. Biomass particles in the spout and freeboard have high temperature and heat-transfer coefficient. Some biomass particles move along the outer wall of draft tube, indicating that the equipment of draft tube can avoid back-mixing by preventing direct contact of particles in the spout and annulus. Increasing the height of draft tube results in larger axial gas flux and higher sand heat-transfer coefficient, while decreases biomass temperature in the spout. The simulation results can offer valuable insights into comprehending intricate reactive gas–solid characteristics and conducting operation and design optimization of spouting apparatus.     

Nature and characteristics of gas–liquid flow regimes in a micro-packed bed reactor

Micro-packed bed reactors (μPBRs) have the advantages of high heat and mass transfer efficiency and excellent safety, and they have been successfully applied to hydrogenation and oxidation reactions. However, the study of gas–liquid flow regimes in the μPBR, which is essential for the mass transfer modeling and reactor scale-up, is still insufficient due to the limitation of micro-scale and complexity of capillary force. In this work, the flow regimes in the two-dimensional μPBR were systematically studied by visual method utilizing a high-performance camera. Four typical flow regimes and characteristics were captured, and flow regime transition was revealed. Effects of gas and liquid superficial velocities, liquid physical properties, and particle sizes on liquid spreading areal fraction and pressure drop were investigated. Flow regime transition correlation of churn flow and pseudo-static flow in the μPBR was provided for the first time based on the summary of the current and previous published results.     

Modeling and operating conditions optimization of Fischer–Tropsch synthesis in a fixed-bed reactor

The effect of a range of operation variables such as pressure, low temperature and H₂/CO molar feed ration the catalytic performance of 80%Co/20%Ni/30 wt% La₂O₃/1 wt% Cs catalyst was investigated. It was found that the optimum operating conditions is a H₂/CO = 2/1 molar feed ratio at 260 °C temperature and 2 bar pressure. Reaction rate equations were derived on the basis of the Langmuir–Hinshelwood–Hougen–Watson (LHHW) type models for the Fischer–Tropsch reactions. The activation energy obtained was 59.69 kJ/mol for optimal kinetic model.     

Micromixing in a gas–liquid vortex reactor

The gas–liquid vortex reactor (GLVR) has substantial process intensification potential for multiphase processes. Essential in this respect is the micromixing efficiency, which is of great importance in fast reaction systems such as crystallization, polymerization, and synthesis of nanomaterials. By creating a vortex flow and taking advantage of the centrifugal force field, the liquid micromixing process can be intensified in the GLVR. Results show that introducing a liquid into a gas-only vortex unit results in suppression of primary and secondary gas flow. The Villermaux–Dushman protocol is applied to study the effects of the gas flow rate, liquid flow rate, and liquid viscosity based on a segregation index. Based on the incorporation model and reaction kinetics, the micromixing time of the GLVR is determined to be in the range of 10⁻⁴ ~ 10⁻³ s, which is comparable to the highly efficient rotating packed bed and substantially better than a static mixer.     

Classification and identification of gas–liquid dispersion states in a jet bubbling reactor

Three gas–liquid dispersion states including flooding, loading, and complete dispersion are observed sequentially in a jet bubbling reactor with an increase of the liquid jet velocity at the nozzle outlet (u_j). The gas–liquid dispersion states are identified through the slope (k) of the curve of fluctuation distribution index (FI) versus u_j as follows: (a) under the flooding, k = 0; (b) under the loading, k > 0; (c) under the complete dispersion, k < 0. In particular, the u_j at the transition points from flooding to loading and from loading to complete dispersion are referred to flooding jet velocity (u_jf, the transition point between k = 0 and k > 0) and complete dispersion jet velocity (u_jcd, the transition point from k > 0 to k < 0), respectively. The average relative deviations of the u_j at the transition points obtained through the acoustic emission measurement and visual observation are less than 5%.     

Profiles of solid fraction and heterogeneous phase structure in a gas–solid airlift loop reactor

The time-averaged and transient local solid fractions in a gas–solid airlift loop reactor (ALR) were investigated systematically by experiments and CFD simulations. To demonstrate the macro-flow pattern, the time-averaged local solid fractions in four regions of the ALR were measured by optical fiber probe under the conditions of different superficial gas velocities and particle circulation fluxes. The experimental results show that the lateral distribution of time-averaged local solid fraction is a core-annulus or heterogeneous structure in the three regions (draft tube, bottom region, particle diffluence region), but a uniform lateral distribution in the annulus. The operating conditions have different effects on the lateral distribution of time-averaged local solid fraction in each region. In the CFD simulation, a modified Gidaspow drag model considering the formation of particle clusters was incorporated into the Eulerian–Eulerian CFD model with particulate phase kinetic theory to simulate and analyze the transient local solid fraction and the two-phase micro-structures in the gas–solid ALR. The predicted values of solid fraction were compared with the experimental results, validating the drag model. The contours of transient flow field indicate that the flow field of the ALR should be divided into five flow regions, i.e., draft tube, annulus, bottom region, particle diffluence region and constrained back-mixing region, which further improves the understanding of the airlift reactor where only four divisions were determined from the experiments. The transient local solid fraction and its probability density function profoundly reveal the two-phase micro-structures (dilute phase and emulsion phase or cluster phase in the constrained back-mixing region) and explain the heterogeneous phenomenon of solid fraction in the ALR. The dilute phase tends to exist in the center of bed, while the emulsion phase mainly appears in the wall region. The results also indicate that the gas–solid ALR has the common characteristic of aggregative fluidization similar to that in normal fluidized beds. The simulated two-phase transient micro-structures provide the appropriate explanations for the experimental core-annulus macro-structures of time-averaged local solid fraction.     

Spray and mixing characteristics of liquid jet in a tubular gas–liquid atomization mixer

For the design and optimization of a tubular gas–liquid atomization mixer,the atomization and mixing characteristics of liquid jet breakup in the limited tube space is a key problem.In this study,the primary breakup process of liquid jet column was analyzed by high-speed camera,then the droplet size and velocity distribution of atomized droplets were measured by Phase-Doppler anemometry (PDA).The hydrodynamic characteristics of gas flow in tubular gas–liquid atomization mixer were analyzed by computational fluid dynamics (CFD) numerical simulation.The results indicate that the liquid flow rate has little effect on the atomization droplet size and atomization pressure drop,and the gas flow rate is the main influence parameter.Under all experimental gas flow conditions,the liquid jet column undergoes a primary breakup process,forming larger liquid blocks and droplets.When the gas flow rate (Q_g) is less than 127 m~3·h~(-1),the secondary breakup of large liquid blocks and droplets does not occur in venturi throat region.The Sauter mean diameter (SMD) of droplets measured at the outlet is more than 140μm,and the distribution is uneven.When Q_g127 m~3·h~(-1),the large liquid blocks and droplets have secondary breakup process at the throat region.The SMD of droplets measured at the outlet is less than 140μm,and the distribution is uniform.When 127Q_g162 m~3·h~(-1),the secondary breakup mode of droplets is bag breakup or pouch breakup.When 181Q_g216 m~3·h~(-1),the secondary breakup mode of droplets is shear breakup or catastrophic breakup.In order to ensure efficient atomization and mixing,the throat gas velocity of the tubular atomization mixer should be designed to be about 51 m·s~(-1)under the lowest operating flow rate.The pressure drop of the tubular atomization mixer increases linearly with the square of gas velocity,and the resistance coefficient is about 2.55 in single-phase flow condition and 2.73 in gas–liquid atomization condition.     

Mixing and recirculation characteristics of gas–liquid Taylor flow in microreactors

The effects of operating parameters (capillary and Reynolds numbers) and microchannel aspect ratio (α=w/h=[1;2.5;4]$\alpha =w/h=[1;2.5;4]$) on the recirculation characteristics of the liquid slug in gas–liquid Taylor flow in microchannels have been investigated using 3-dimensional VOF simulations. The results show a decrease in the recirculation volume in the slug and an increase in recirculation time with increasing capillary number, which is in good agreement with previous results obtained in circular and square geometries (Thulasidas et al., 1997). In addition, increasing the aspect ratio of the channel leads to a slight decrease in recirculating volumes but also a significant increase in recirculation times.     

Fundamental studies on the hydrodynamics and mixing of gas and solid in a downer reactor

The effect of flow direction on hydrodynamics and mixing in the upflow and downflowcirculating fluidized beds is discussed in details.Similar profiles of gas and solids velocities andsolids concentration are found in both risers and downers.When the flow is in the direction ofgravity(downer),the radial profiles of gas and particle velocity are more uniform than that inthe riser,the solids mixing is very small and the flow pattern approaches plug flow,while theflow is against gravity(riser),the solids backmixing significantly increase and the flow pattern isfar from plug flow.Among many of factors the flow direction has the largest influence onhydrodynamics and axial mixing of gas and solids.     

Simulation analysis of gas–solid flow characteristics and water evaporation in flue gas semi-dry desulphurization process based on CPFD method

The gas–solids flow in an industrial-scale semi-dry method desulphurization tower is simulated by the computational particle fluid dynamics (CPFD) approach. Compared with previous studies on desulphurization towers, this study focuses on analyzing particle distribution characteristics such as particle volume fraction, temperature distribution, and residence time. The simulation fully considered the particle–fluid, particle–particle, and particle–wall interactions in the desulphurization tower. Based on these considerations, the effects of flue gas inlet velocity and temperature on the gas–solid distribution characteristics of the desulphurization tower are simulated. An optimization scheme for adjusting the gas–solid flow in the desulphurization tower is proposed. The research results show that the error between the CPFD simulation data and experimental data is small and the changing trend is consistent. The particles in the bed of the desulphurization tower show a typical core–annulus flow. The distribution of gas and particles in the bed has a serious deviation with the increase of the flue gas inlet velocity and temperature. As the axial height of the desulphurization tower increases, the flue gas velocity, temperature, particle concentration, and water vapour distribution in the bed become more uniform. The relatively stable operating conditions for the gas–solid flow in the desulphurization tower is that the flue gas inlet velocity and temperature are 15 m/s and 393 K, respectively. Under these operating conditions, the pressure loss caused by the venturi accounted for 73.6% of the total pressure loss of the desulphurization tower. When the particle radius is between 0–150 μm, the particle size and the flue gas inlet velocity have the greatest influence on the particle residence time. Finally, the distribution of gas and particles before and after the adjustment of the desulphurization tower is compared, which showed that adjusting the bottom structure of the desulphurization tower could optimize the gas–solid flow.     

Slug flow characteristics of gas–miscible liquids in a rectangular microchannel with cross and T-shaped junctions

The slug flow of an inert gas and two miscible liquids in microchannels has found its applications in the preparation of solid lipid nanoparticles (SLNs) by the liquid flow-focusing together with Taylor bubbles in microchannel systems, synthesis of metal nanoparticles or colloid silica in microreactors and enhancement of micro-mixing by interaction using gas bubbles in microfluidic devices. In this work, the flow characteristics of the slug flow generated by nitrogen gas and two miscible liquids (the aqueous surfactant solution and acetone or ethanol) flowing in a rectangular microchannel were investigated experimentally by using the high-speed optical imaging method. The microchannel system has a straight main channel for introducing one of the miscible liquids, a cross-junction for injecting of the other miscible liquid, and a T-junction for feeding the gas phase. The pressure drops were measured and images of Taylor bubbles and slug units at various velocities were obtained, from which other flow parameters were determined. Correlations for the velocity and length of Taylor bubbles, the bubble nose length, the bubble tail length, the liquid slug length, the maximum and minimum thicknesses of the liquid films around bubbles, as well as the pressure drop, were proposed. The calculated values of these parameters by using the correlations were compared with the experimental data. The results showed that the proposed correlations are in a good or reasonable agreement with experimental data and then expected to be available in the estimation of the slug flow parameters of the inert gas and two miscible liquids in rectangular microchannels.     

Numerical simulation of local and global mixing/segregation characteristics in a gas–solid fluidized bed

Researches on solids mixing and segregation are of great significance for the operation and design of fluidized bed reactors. In this paper, the local and global mixing and segregation characteristics of binary mixtures were investigated in a gas–solid fluidized bed by computational fluid dynamics-discrete element method (CFD-DEM) coupled approach. A methodology based on solids mixing entropy was developed to quantitatively calculate the mixing degree and time of the bed. The mixing curves of global mixing entropy were acquired, and the distribution maps of local mixing entropy and mixing time were also obtained. By comparing different operating conditions, the effects of superficial gas velocity, particle density ratio and size ratio on mixing/segregation behavior were discussed. Results showed that for the partial mixing state, the fluidized bed can be divided into three parts along the bed height: complete segregation area, transition area and stable mixing area. These areas showed different mixing/segregation processes. Increasing gas velocity promoted the local and global mixing of binary mixtures. The increase in particle density ratio and size ratio enlarged the complete segregation area, reduced the mixing degree and increased the mixing time in the stable mixing area.     

Comparative study of gas–oil and gas–water two-phase flow in a vertical pipe

A wire-mesh sensor has been employed to study air/water and air/silicone oil two-phase flow in a vertical pipe of 67 mm diameter and 6 m length. The sensor was operated with a conductivity-measuring electronics for air/water flow and a permittivity-measuring one for air/silicone oil flow. The experimental setup enabled a direct comparison of both two-phase flow types for the given pipe geometry and volumetric flow rates of the flow constituents. The data have been interrogated at a number of levels. The time series of cross-sectionally averaged void fraction was used to determine characteristics in amplitude and frequency space. In a more three-dimensional examination, radial gas volume fraction profiles and bubble size distributions were processed from the wire-mesh sensor data and compared for both flow types. Information from time series and bubble size distribution data was used to identify flow patterns for each of the flow rates studied.     

Gas and soot products formed in the pyrolysis of acetylene–ethanol blends under flow reactor conditions

The present paper reports a laboratory study on the pyrolysis of different blends containing acetylene, known as an important soot precursor, and ethanol, regarded as an appropriate additive to conventional fuels aiming to diminish the emission of pollutants coming from combustion processes. Pyrolysis experiments of acetylene–ethanol blends, for a total initial concentration of reactants of 50,000 ppm, with variable volume percentages of ethanol between 0 and 40% with respect to the total concentration of reactants, have been carried out in a quartz flow reactor working in a temperature range of 975–1475 K. The influence of both pyrolysis temperature and ethanol concentration in the blend on the gas and solid products has been evaluated. As the reaction temperature is increased, the soot production is higher and yield to carbonaceous gas products decreases. It is noticed that the presence of ethanol inhibits the production of soot and the diminution of soot formation does not present a linear dependency with the ethanol concentration; the influence is comparatively stronger when adding small amounts of ethanol. The analysis of the gas products reveals that increasing the ethanol percentage in the blend causes an increase of the concentration of some intermediates such as ethylene, ethane, methane or benzene, pointing to a variation of the reacting species which could prevent soot formation. A literature detailed gas phase kinetic mechanism including reaction subsets for acetylene and ethanol conversion has been used to simulate the experimental results. This theoretical study has been carried out with the purpose of analyzing the trends of the evolution of gas products and getting a better understanding of the gas phase processes involved in the pyrolysis of the different blends, although soot formation is not included.     

Bed density and circulation mass flowrate in a novel annulus-lifted gas–solid air loop reactor

Air loop reactors (ALR) have been widely used as promising and high-efficiency gas–liquid and gas–liquid–solid reactors. Extensive research on ALR has been conducted, but mostly limited to gas–liquid and gas–liquid–solid systems. Work associated with gas–solid systems has been rare and mainly focused on draft tube-lifted spouted bed treating coarse Geldart B, D particles. The present paper proposed a novel gas–solid air-loop reactor treating fine Geldart A particles and operating in a new annulus-lifted mode, with bubbling or turbulent bed upward flow in the annulus in parallel with bubbling bed downward flow in the draft tube. In view of these differences, distinct hydrodynamic behaviour can be anticipated for the gas–solid annulus-lifted air-loop reactor. The influence of operating conditions and geometric configuration on the distribution of bed density is discussed in a cold model annulus-lifted air loop reactor. A mechanistic model for the circulation mass flowrate is established based on an energy balance and resistance analysis. Nearly 50% and 30% of the energy dissipation rate occurs in the bottom and top regions, respectively. With increasing draft tube height, the energy dissipation rate increases in the annulus and draft tube regions, while it decreases in the top and bottom regions. The circulation mass flowrate decreases with increasing draft tube height. Analysis of the distribution of bed density and energy dissipation rate leads to suggestions regarding optimization of the design and axial location of the ring distributor and gap height.     

Local and global gas–liquid mass transfer in a micro-packed bed reactor utilizing a noninvasive colorimetric technique

Micro-packed bed reactor (μPBR) presents great potential in the field of multiphase reactions due to the features of safety and high efficiency. However, the deeper cognition of mass transfer needs to be taken into consideration that is the foundation of reactor design. In this work, local and global gas–liquid mass transfer in the μPBR were studied utilizing a noninvasive colorimetric technique. In reactor level, the qualitative and quantitative comparisons were conducted; in particle level, liquid flow and mass transfer textures were assessed for the first time. The diversities of local mass transfer characteristics from temporal and spatial dimensions were obtained, and the heterogeneity of local and global mass transfer was revealed. The predicted correlations of $$ in μPBR with churn flow and pseudo-static flow were established with deviations generally within ±18%. This study contributes to improve the understanding of mass transfer and points out the process intensification direction of μPBR.     

N-shape pressure drop curve of gas–liquid microchannel reactor and modeling

Accurate prediction of gas–liquid pressure drop is essential to microreactors design; however, the understanding of general rules of pressure drop in a wide gas–liquid flow ratio, especially smaller than 1.0, remains insufficient, Accordingly, this work systematically studies the pressure drop rule within the gas–liquid flow ratio of 0.2–2.0. The results show that, under a given gas velocity, the pressure drop first increases and then decreases, and finally back increases with the liquid flow velocity, and the named N-shape pressure drop curve could be clearly observed. Besides, the rules of gas–liquid unit length and gas-phase holdup are explored to reveal the mechanism behind the N-shape pressure drop curve. Finally, three semi-empirical correlations based on the gas–liquid unit length and separated flow model are successfully proposed for the N-shape pressure drop. This work provides some important fundamental information for the reliable design of gas–liquid microreactors.     

Methanation of carbon dioxide and fluidization quality in a fluid bed reactor—the influence of a decrease in gas volume

A large decrease of fluidization quality was observed when methanation of carbon dioxide was carried out in a fluid-bed reactor even if the catalyst particles had the optimal properties for good fluidization. The cause of this phenomenon was explored by measuring pressure fluctuations, bubble frequency and extent of CO₂ conversions. The results indicated that the decrease of the fluidity was caused by a reduction in volume of reactant gases due to the reaction. The voidage in the emulsion phase is considered to be an important factor affecting the fluidity. The fluidization quality and contacting efficiency could be improved by such devices as baffle internals or two-stage spargers.     

SMCA—the real optimal operation of a multistage adiabatic fixed-bed reactor

A general rule and a straightforward approach of the real optimal operation of a multistage adiabatic fixed-bed reactor (MAFBR) for a single reaction system, namely, the stagewise maximum conversion approach (SMCA), were derived based on the analysis of the operation of a Fauser—Montecatini type, five-stage ammonia synthesis reactor. The SMCA can be implemented in reactors which have ageing catalysts and maldistributed gas. The SMCA has been applied efficiently to industrial SO₂ oxidation and NH₃ synthesis plants. Suggestions on the design of a new MAFBR are made.