Gas back-mixing studies in membrane assisted bubbling fluidized beds

Fluidized beds employing fine powders are finding increased application in the chemical and petrochemical industry because of their excellent mass and heat transfer characteristics. However, in fluidized bed chemical reactors axial gas back mixing can strongly decrease the conversion and selectivity. By insertion of membranes in fluidized beds large improvements in conversion and selectivity can be achieved, firstly by optimizing axial concentration profiles via distributive feeding of one of the reactants or selective withdrawal of one of the products, and secondly, by decreasing the effective axial dispersion via compartmentalization of the fluidized bed. Moreover, insertion of membrane bundles in a suitable configuration impedes bubble growth, thereby reducing reactant by-pass via rapidly rising large bubbles. In this work the influence of the presence and configuration of membrane bundles and the effect of gas addition via the membranes on the effective axial dispersion was studied experimentally.Steady state concentration profiles were measured where a CO₂-tracer was injected at different locations through a probe (point injection) or via the membranes (line injection) into a square fluidized bed containing glass particles (75-, 2550 kg/m³) fluidized with nitrogen distributed via a porous plate. Different bed configurations, viz. without internals, with vertical or horizontal membrane bundles were investigated and the effects of overall fluidization velocity and gas flow ratio of gas fed through the membrane bundles and the porous plate distributor were studied.Experimental results revealed that the insertion of vertical and horizontal membrane bundles decreases the effective axial dispersion considerably compared to a bed without internals. The point injection experiments indicated the importance of a non-uniform lateral emulsion phase velocity profile. The line injection experiments clearly pointed out the importance of bubble-to-emulsion phase mass transfer limitations. Gas addition through the membrane bundles decreases the effective axial gas dispersion enormously by almost annihilating the solids down flow along the walls and by decreasing the average bubble size and bubble fraction.     

On the formation of Taylor bubbles in small tubes

The formation of Taylor bubbles and resulting bubble lengths were studied in a ID vertical tube for air-water and air-octane systems. In the co-flow tube/nozzle arrangement two nozzle sizes were used as gas inlets. Superficial velocities varied between 0.001- for the liquid and 0.002- for the gas. Three different mechanisms of initial bubble formation were observed. Of the three mechanisms, mechanism 3 is periodic (with period consisting of a bubble and a liquid slug), reproducible and can be simply modelled. After initial bubble formation further modifications may occur in the formed bubble size by coalescence or pairing. Bubble pairing is encouraged by smaller nozzles and liquid flow rates, while coalescence is observed only for cases where non-Taylor bubbles form initially.Two simple models have been proposed, the first predicts the size of the Taylor bubbles formed by mechanism 3 while the second attempts to predict the condition for bubble pairing to occur. Reasonable agreement with experimental results validates the predictions of the first model for a strong dependence of the volume of Taylor bubbles formed on the gas and liquid flow rates, a moderate dependence on nozzle diameter and a weak dependence (if at all) on the surface tension of the liquid used. Mismatch with the experimental results is caused (at least in part) by the experimental setup where there was no perfect axial alignment of the gas inlet. The experiments also suffered from problems at the outlet at low flow rates where smooth bubble disengagement could not be ensured for long Taylor bubbles. The second model for pairing predicts its occurrence for concentric tube/nozzle arrangements as a function of flow rates and channel diameters. The model over-predicted the range of liquid flow rates at which pairing was observed experimentally, but it captured the form of the boundary between different bubble volume modification mechanisms when represented on superficial velocity graphs.     

CFD simulation of gas solid flow in FCC strippers

In this paper, the hydrodynamic characteristics in bubbling fluidized beds (FCC Strippers) were simulated by using computational fluid dynamics (CFD) code (Fluent 6.2.16). The modified Gidaspow drag model based on the effective mean diameter of the particle clusters predicted the expected bubbling fluidization behavior and bed expansion. Compared with the bed densities of in the empty-cylinder stripper, bed densities in the V-baffled stripper were at the superficial gas velocity of 0.10-0.20 m/s. The overall trend of the time-averaged bed density at various superficial gas velocities were in agreement with the experimental data. The results illustrated that internal baffles had an important effect on the fluidization hydrodynamics. Internal baffles improved break-up and redistribution of bubbles and intensified the gas-solid contact. The simulation results also indicated that appropriate modification of the internal configuration eliminated the dead flow region in the strippers, and enhanced the gas-solid mixing remarkably, showing benefit for the mass and heat transfer in the fluidized bed.     

Bubble formation from a free-standing tube in microgravity

The bubble characteristics and the bubble detachment mechanisms during injection of air from a free-standing capillary tube submerged in water were studied in microgravity. The experiments were conducted in the 2.2-s drop tower at the NASA Glenn Research Center. A tube, 0.51 mm in diameter and 150 mm long, in a rectangular test section ( long) served as the injector. Images of the bubbles during the drops were acquired using a high-speed camera for various gas flow rates. Bubble detachment was observed for all the Weber numbers tested (0.28-31.12). This observation was different from previous studies using plate orifices in microgravity when bubble detachment was observed only for Weber numbers larger than 8. In order to resolve these differences, experiments were carried out using plate orifices. It was found that the bubbles detached from the orifice for all Weber numbers and that the bubbles formed were larger than those formed with the tube injector, particularly at low gas flow rates. The availability of a large area for the bubble to anchor itself and the presence of the chamber underneath the orifice could cause these differences. The effects of the chamber volume on the unsteadiness of bubble formation in plate-orifices at low gas flow rates are discussed.     

Coalescence during bubble formation at two neighbouring pores: An experimental study in microscopic scale

This work studies the effect of the liquid properties and the operating conditions on the interactions between under-formation bubbles in a cell equipped with two adjacent micro-tubes (i.d. ) for the gas injection, placed 210, 700 and apart. This set-up simulates, though in a simplified manner, the operation of the porous sparger in a bubble column, and it is used to study the bubble interactions observed on the sparger surface. Various liquids covering a wide range of surface tension and viscosity values are employed, while the gas phase is atmospheric air. A fast video recording technique is used both for the visual observations of the phenomena occurring onto the tubes and for the bubble size measurements. The experiments reveal that the interactions between under-formation bubbles as well as the coalescence time depend strongly on the liquid properties, the distance between the tubes and the gas flow rate. Two correlations, which can be found helpful for the bubble column design, have also been formulated and are in good agreement with the available experimental data.     

Annulus leakage and distribution of the fluid flow in a liquid spout-fluid bed with a draft tube

The distribution of flow between the annulus and the draft tube sections in a liquid phase spout-fluid bed with a draft tube was studied in a flat-based semi-circular column of diameter equipped with a semi-circular draft tube of diameter at superficial fluid velocities well above the minimum fluidization velocity. The particles used were glass spheres of diameter, and the spouting medium was tap water. A sodium chloride solution was injected into the reactor and the response recorded to determine the flow distribution between the draft tube and the annulus sections. The responses of the tracer injections prove that part of the flow originating from the annulus inlet leaks into the draft tube when any amount of annulus inlet flow is present. This finding makes a significant contribution to the understanding of the entrance region below a draft tube which has been modeled as a spout-fluid bed where fluid enters the annulus region based on the pressure distribution at the spout-annulus interface while the flow is in the radial direction from the spout into the annulus. This work shows that there is cross flow in the entrance region resulting in fluid exchange between the streams originating from the spouting inlet nozzle and the annulus inlet flow.The amount of leakage is found to increase with increasing inlet flow rates. An empirical correlation is developed to predict the fraction of the leakage of the annulus inlet flow. The superficial fluid velocity through the draft tube is found to vary linearly with the total flow rate through the bed under the experimental conditions studied. The pressure distributions in the entrance region favor the leakage of fluid from the annulus inlet flow into the draft tube.     

Bubble sizes in agitated solvent/reactant mixtures used in heterogeneous catalytic hydrogenation of 2-butyne-1,4-diol

Catalytic hydrogenations reactions are frequently conducted in “dead-end” multiphase stirred reactors with the reactant dissolved either in an alcohol, or in water or a mixture of the two. In such systems, the rate of gas-liquid mass transfer, which depends on bubble size, may well be the overall rate-limiting step. However, a study of bubble sizes across the whole range of solvent compositions from entirely water to entirely organic has not been reported. Here, for the first time, a systematic investigation has been made in a 3 L, closed vessel simulating a “dead-end” reactor containing 1% by volume of air which is dispersed by a Rushton turbine in water, isopropanol (IPA) and mixtures of the two, with and without 2-butyne-1,4-diol simulating a reactant. Mean specific energy dissipation rates, , up to have been used and bubbles size distributions and mean size were measured using a video-microscope-computer technique. In the single component solvents (water, ; IPA, though the interfacial tensions are very different, irregular, relatively large bubbles of similar sizes were observed ( in IPA, and in water) with a wide size distribution. In the mixed aqueous/organic solvents, and especially at the lower concentrations of IPA (1%, 5%, 10%), the bubbles were spherical, much smaller (d₃₂ from 50 to ) with a narrow size distribution. The addition of the reactant (0.2 M 2-butyne-1,4-diol) to the mixed solvents had little effect on the mean size, shape or distribution. However, addition to water (thus producing a mixed aqueous/organic liquid phase) led to small spherical bubbles of narrow size distribution. Neither Weber number nor surface tension was suitable for correlating bubble sizes since σ decreased steadily from pure water to IPA whilst bubble size passed through a minimum at around 5% IPA. For any particular fluid composition, the functionality between d₃₂ and was similar, i.e. . The above observations are explained in terms of the polarisation of bubble surfaces in miscible mixed aqueous/organic liquids caused by preferential directional adsorption at low concentrations of the organic component with its hydrophilic part directed into the aqueous phase and its hydrophobic part into the gas phase. As a result, coalescence is heavily suppressed in the low-concentration miscible alcohol (or diol)/aqueous systems whilst strong coalescence dominates bubble sizes in water and the alcohol and at high concentrations of the latter.     

Small bubble formation via a coalescence dependent break-up mechanism

A mechanism has been elucidated for the coalescence-mediated break-up of bubbles in gas-liquid systems. Images taken from dynamic systems (a coalescence cell and laboratory-scale bubble columns) show that in some instances the coalescence of two bubbles is accompanied by the formation of a much smaller daughter bubble. Following the coalescence process an annular wave is formed due to the very rapid expansion of the hole following the instant of film rupture. As the wave moves along the length of the bubble, away from the point of rupture it causes a rippling effect which distorts the newly coalesced bubble and may result in the formation of an unstable extension. Instabilities due to the annular wave pinch off a portion of this extension, resulting in the generation of a small daughter bubble. In coalescence dominated systems the process results in the generation of significant numbers of bubbles much smaller (100- diameter) than the Sauter mean diameter (3-).     

Dynamically enhanced membrane foaming

Foamed food products like chocolate mousse, ice cream or fresh cheese are increasingly popular due to their soft and creamy sensory properties. Their perception, stability and flow behavior strongly depend on gas fraction and bubble size distribution. Foam processing research focuses on developing new optimized processes and material systems to achieve small mean bubble size and narrow size distribution.In this work, we present a new dynamically enhanced membrane foaming process. This foaming device basically consists of two concentric cylinders: the inner cylinder is rotated with circumferential velocities up to , the outer cylinder is fixed. Thus, a shear field is created in the narrow annular gap. The membrane can either be mounted to the inner or outer cylinder. Gas is pressed through the membrane and is detached as small bubbles by the acting flow shear stresses. The comparison of rheological and microstructural analysis of foams to results on bubble breakup in simple shear flow and on detachment of bubbles from the pore of a rotating membrane proved that the detachment of small bubbles from the membrane is the dominating bubble formation process in the dynamically enhanced membrane foaming process. Compared to conventional rotor-stator foaming devices, the dynamically enhanced membrane foaming process leads to significantly smaller mean bubble sizes at higher gas volume fractions and to reduced size distributions widths.     

Discrete element simulation of a flat-bottomed spouted bed in the 3-D cylindrical coordinate system

A spouted bed is simulated in three dimensions by a discrete element method (DEM) in a cylindrical coordinate system. The numerical scheme is based on a second order finite difference method in space and a second order Adams-Bashforth method for time advancement. Gas-particle interaction is assumed to obey the Ergun equation (for void fraction less than 0.8) and its corrected model by Wen and Yu (for void fraction greater than 0.8). The spouted bed vessel is a flat-bottomed cylinder in height and in diameter. The gas inlet diameter is . Three hundred thousand monosized spheres of diameter are used in the simulation. The typical characteristics of spouted beds, such as spout, annulus and fountain, are reproduced. Particle velocity profiles show good agreement with experimental results and self-similarity of the radial distribution of axial particle velocities is reported. Gas flow patterns are also studied and the effect a vortex ring fixed at the bottom of the vessel is investigated. The simulation is validated through comparisons with results reported in the literature.     

Physical modelling and similitude of air bubble entrainment at vertical circular plunging jets

When a plunging jet impinges into a pool of liquid, air bubble entrainment takes place if the inflow velocity exceeds a threshold velocity. This study investigates air entrainment and bubble dispersion in the developing flow region of vertical circular plunging jets. Three scale models were used and detailed air-water measurements (void fraction, bubble count rate, bubble sizes) were performed systematically for identical inflow Froude numbers. The results highlight that the modelling of plunging jet based upon a Froude similitude is affected by significant scale effects when the approach flow conditions satisfied We₁<1E+3, while some lesser scale effect was noticed for V₁/u_r<10 and We₁>1E+3. Bubble chord time measurements showed pseudo-chord sizes of entrained bubbles ranging from less than to more than with an average pseudo-chord size were between 4 and . However, bubble size data could not be scaled properly.     

Fluidization behavior in a circulating slugging fluidized bed reactor. Part II: Plug characteristics

In the transporting square nosed slugging fluidization regime () a bed of polyethylene powder with a low density () and a large particle size distribution () was operated in two circulating fluidized bed systems (riser diameters 0.044 and 0.105 m). A relation was derived for the plug velocity as a function of the gas velocity, solids flux, riser diameter, particle size range and particle and powder properties. The influence of the plug length on the plug velocity, the raining rate of solids onto and from the plugs and the influence of the particle size range on the plug velocity is accounted for.     

Tomographic analysis of dry and semi-wet bed fluidization: the effect of small liquid loading and particle size on the bubbling behaviour

The hydrodynamic changes resulting from the addition of very small quantities of a non-volatile liquid into a cold conventional fluidized bed has been investigated, and compared with the effects of increasing the particle size in a dry bed. Three different particle mixtures belonging to Group A/B, Group B and Group B/D were assessed. The changes in regime transition velocities, pressure drop, bubble rise velocity, bubble frequency and bubble flow rate have been quantified by employing Electrical Capacitance Tomography measurements. A new analysis method for measuring the effective interparticle forces (F_ip) and the effective drag force (F_d) in a dry fluidized bed is described, and the results are presented in terms of different force ratios including the single particle weight (W). It is shown that the addition of a few drops of liquid to a dry bed of Group B or B/D introduces similar hydrodynamic changes (except, in terms of bubble frequency) as that of increasing the bed particle size, and these particular changes shift the powders away from Group A/B behaviour. It is also illustrated that for beds of different particle sizes, a typical bubbling behaviour can be achieved at a specific gas velocity, this velocity coincides with the point of equality in hydrodynamic force ratios and E_ip/F_d.     

Effect of gas expansion on the velocity of individual Taylor bubbles rising in vertical columns with water: Experimental studies at atmospheric pressure and under vacuum

This study was designed to determine the effect of gas expansion on the velocity of Taylor bubbles rising individually in a vertical column of water. This experimental study was conducted at atmospheric pressure or under vacuum (33.3 and ) using three different acrylic columns with internal diameters of 0.022, 0.032, and 0.052 m, and more than 4.0 m high. A non-intrusive optical method was used to measure velocity and length of Taylor bubbles at five different locations along the columns. The operating conditions used correspond to inertial controlled regime.In experiments performed under vacuum, there is considerable gas expansion during the rise of Taylor bubbles, particularly when they approach the liquid free surface where the pressure drop (due to the hydrostatic pressure) is of the order of magnitude of the absolute pressure. The liquid ahead of the bubble is displaced upward by an amount proportional to the gas expansion resulting in increased bubble velocity. The calculated Reynolds number suggests a laminar regime in the liquid ahead of the bubble. However, the experimentally determined velocity coefficient C for each column was much smaller than 2, which would be expected for laminar flow. The value of C obtained ranges from 1.13±0.09, for the narrowest column, to 1.40±0.24, for the widest column. This suggests that a fully developed laminar flow in the liquid ahead of the bubble is never achieved due to continuous bubble expansion at a variable rate, regardless of column height.The velocity coefficient C can be used to calculate the contribution of liquid motion to bubble velocity. Subtracting this contribution from the measured bubble velocity defines a constant value which is nearly identical to the bubble rise velocity measured in the same column operated as a constant volume system (two ends closed) where gas expansion is absent.     

Role of hydrodynamic flow parameters in lipase deactivation in bubble column reactor

The dynamic environment within the bioreactor and in the purification equipment is known to affect the activity and yield of enzyme production. In the present work, the effect of hydrodynamic flow parameters and τ_N,max) and interfacial flow parameters ( and ) on the activity of lipase has been comprehensively investigated in bubble column reactors. Lipase solution was subjected to hydrodynamic flow parameters in 0.15 and 0.385 m i.d. bubble column reactors over a wide range of superficial gas velocity (0.01<V_G<0.4-). The flow parameters were estimated using an in-house CFD simulation code based on k-ε approach. The extent of lipase deactivation in both the columns was found to increase with an increase in hydrodynamic and interfacial flow parameters. However, at equal value of any of these parameters, the extent of deactivation was different in the two columns. The rate of deactivation was found to follow first order kinetics. An attempt has been made to develop rational correlations for the extent of deactivation as well as for the deactivation constant. The rate of deactivation was found to be depending on the average turbulent normal stress and interfacial flow parameters such as bubble diameter and bubble rise velocity.     

Flow behavior and regime transition in a high-density circulating fluidized bed riser

Flow behavior and flow regime transitions were determined in a circulating fluidized bed riser (0.203 m i.d. × 5.9 m high) of FCC particles (, ). A momentum probe was used to measure radial profiles of solids momentum flux at several heights and to distinguish between local net upward and downward flow. In the experimental range covered (; ), the fast fluidization flow regime was observed to coexist with dense suspension upflow (DSU). At a constant gas velocity, net downflow of solids near the wall disappeared towards the bottom of the riser with increasing solids mass flux, with dense suspension upflow achieved where there was no refluxing of solids near the riser wall on a time-average basis. The transition to DSU conditions could be distinguished by means of variations of net solids flow direction at the wall, annulus thickness approaching zero and flattening of the solids holdup versus G_s trend. A new flow regime map is proposed distinguishing the fast fluidization, DSU and dilute pneumatic transport flow regimes.