Analysis of packed distillation columns with a rate-based model

Multicomponent packed column distillation is simulated using a rate-based model and the simulation results are compared with the experimental results obtained from a 0.2 m diameter pilot-scale packed column. The simulation algorithm used is previously proposed by the authors, which based on an equation-tearing method for (6c+7) equations of one packing segment and the whole column is solved by an iterative segmentwise calculation with the overall normalized θ method for acceleration. The performance of two packings is examined by simulating the pilot-scale column experiments using the published correlations for estimating liquid and vapor phase mass transfer coefficients and an effective interfacial area.     

CONDENSATION HEAT TRANSFER OF VAPOR-GAS MIXTURE IN TURBULENT FLOW THROUGH AN ANNULUS

Condensation heat transfer of vapor-gas mixture in turbulent downflow through a vertical annulus has been studied. An analytical model, relatively simple in computation, is developed using available correlations for the interfacial shear stress, heat and mass transfer coefficients. The solutions obtained for steam-air mixtures agree well with experimental data of Stewart et al. and Kasprzak and Podpora. The effects of main stream Reynolds number and radius ratio r* are found to be significant for flow condensation of mixtures in annuli.     

Mass transfer with chemical reaction in liquid foam reactors

Mass transfer studies were conducted in a stable liquid foam reactor under various operating conditions to evaluate gas holdup, effective interfacial area, liquid-phase mass transfer coefficient and a modified interfacial mass transfer coefficient to include the surface-active agents employed. Gas holdup and effective interfacial area were evaluated experimentally. The interfacial mass transfer coefficient was evaluated semitheoretically, by considering the interfacial region as a separate phase and using the experimental data developed for mass transfer accompanied by a fast first-order chemical reaction. The liquid-phase mass transfer coefficient was also evaluated semitheoretically, using Danckwert's theory for the liquid phase and the experimental data on mass transfer accompanied by a slow pseudofirst-order chemical reaction. An experimental unit was set up to provide a stable flowing foam column, simulating the foam reactor. Mass transfer rates were studied for superfacial gas velocities in the range from 1.5 × 10⁻² m/s to 5 × 10⁻² m/s, giving gas residence times in the range from 20 to 55 seconds. A cationic and nonionic surface-active agent and three different wire mesh sizes, giving bubble size distributions in the range from 2.2 to 5.4 mm Sauter mean diameters, were employed. It is observed that gas holdup is insensitive to the type of surface-active agent; it is however, dependent on wire mesh size and gas velocity. The bubble diameter and, hence, the interfacial area are found to be insensitive to gas velocity in the range studied; they are, however, strong functions of wire mesh size. The liquid-phase mass transfer coefficient increases with increase in gas velocity. The surface-active agent introduces additional resistance to mass transfer in both reaction cases, this being the controlling one in the case of the fast reaction. A comparison with conventional packed bed contactors indicates the mass transfer rates to be about 8 times lower for the foam reactor, for the fast reaction case; for slow reactions, the foam reactor has mass transfer rates approximately 2-4 times higher than those for conventional packed bed contactors.     

HYDRODYNAMICS AND MASS TRANSFER IN BUBBLE COLUMNS: EFFECT OF SOLIDS

The hydrodynamics and mass transfer in a large diameter bubble column (D_c 0.305 m), specifically, the effects of gas velocity and the presence of solids on the gas holdup structure, gas-liquid interfacial area, and volumetric mass transfer coefficients in viscous as well as low viscosity solutions are studied. The sulfite oxidation technique was employed to measure the gas-liquid interfacial area. Volumetric mass transfer coefficients were measured using a chemical method (sulfite oxidation) as well as physical absorption of oxygen from air, and the overall gas holdups were measured using the hydrostatic head technique. The effect of solids on the gas holdup structure was examined using the dynamic gas disengagement method. With the addition of polystyrene particles, the gas-liquid interfacial area decreased for low viscosity systems, whereas it increased for viscous systems. This was shown to be due to the effect of solids on bubble coalescence. The wettability characteristics of solid surfaces in the presence of different liquids have been suggested as the reason for the effect of solids on coalescence. Oil shale slurries presented a special case because of the mineral dissolution effect.     

Effect of shape and wettability of packing materials on the efficiency of packed column

Effective interfacial area and mass transfer coefficient were determined by the use of Danckwerts’ plot method for chemical absorption system accompanied by first order reaction to elucidate the effect of shape and wettability of packing materials on these parameters. The liquid phase used in this experiment was K₂CO₃-KHCO₃ buffer solution, and NaOCl was used to catalyze the first order reaction in the liquid phase. Raschig ring, sequare, sphere in shapes, and these were made of ceramic, polypropylene, glass, stainless steel, were used as packing materials. The following correlations were obtained to predict the effective interfacial area and mass transfer coefficient. a/a_t,=0. 614R^0.161(Σ_c/Σ)^0.119 (a_t,d_n (1-ε)^1/3)^-1.01 K_L = 0. 0154Re^0.24(Σ_c/Σ) {ie001-01} (a_td_n)^0.18     

Interfacial area concentration in boiling bubbly flow systems

The interfacial area, which describes available area for the interfacial transfer of mass, momentum and energy, is a crucial parameter in a two-fluid model formulation. From this point of view, this study performed (i) extensive survey on existing models and correlations developed for boiling bubbly flows, (ii) extensive survey on existing interfacial area database for boiling bubbly flows, (iii) formulation of the physical model based on bubble number density transport equation, (iv) simplification of the model to identify the dominant parameters governing the interfacial area, and (v) finalization of the model based on the collected extensive data and development of the interfacial area correlation. The developed correlation of the interfacial area concentration agreed with 569 adiabatic flow data and 343 boiling flow data within averaged relative deviations of ±21.1% and ±31.0%, respectively.     

Internal water and heat transfer in capillary porous bodies

A mathematical model is suggested for water and heat transfer in a capillary porous body. The driving forces of the transfer are approximated by the transfer (concentration, thermal, filtration) potential drops averaged over the body’s surface and volume. The internal mass and heat transfer coefficients, involved in the model, are determined with the use of the regular regime theory.     

Studies on the liquid-liquid interfacial mass transfer process using holographic interferometry

This paper aims at the interfacial phenomena of liquid-liquid mass transfer and its characteristic. By using the real-time holographic technique, the concentration distributions on the aqueous side were obtained according to holographic diagrams of mass transfer of ethanol through the interface of oil and water at different initial concentrations. Furthermore, the concentrations near the interface and the mass transfer coefficients were attained. A correlation of concentration near the interface to the concentration of the solute in the oil side was proposed. An approach of interfacial energy with solute concentration was established, and the calculated results are at good agreement with the experimental data. It is indicated that the liquid-liquid mass transfer process is approximately in accordance with two-film theory, the interfacial performance may be changed by the addition of the solute, and the interface of liquid-liquid is nonequilibrium thermodynamically during the mass transfer process. __________ Translated from Chemical Engineering (China), 2007, 35(6): 1–3 [译自: 化学工程]     

HYDRODYNAMICS AND MASS TRANSFER IN BUBBLE COLUMNS: EFFECT OF SOLIDS

The hydrodynamics and mass transfer in a large diameter bubble column (D_c 0.305 m), specifically, the effects of gas velocity and the presence of solids on the gas holdup structure, gas-liquid interfacial area, and volumetric mass transfer coefficients in viscous as well as low viscosity solutions are studied. The sulfite oxidation technique was employed to measure the gas-liquid interfacial area. Volumetric mass transfer coefficients were measured using a chemical method (sulfite oxidation) as well as physical absorption of oxygen from air, and the overall gas holdups were measured using the hydrostatic head technique. The effect of solids on the gas holdup structure was examined using the dynamic gas disengagement method. With the addition of polystyrene particles, the gas-liquid interfacial area decreased for low viscosity systems, whereas it increased for viscous systems. This was shown to be due to the effect of solids on bubble coalescence. The wettability characteristics of solid surfaces in the presence of different liquids have been suggested as the reason for the effect of solids on coalescence. Oil shale slurries presented a special case because of the mineral dissolution effect.     

Extraction of rare earth metals with a multistage mixer-settler extraction column

Extraction behavior of rare earth metals within a mixer-settler extraction column has been analyzed with the stage efficiency calculated from mass transfer coefficients and interfacial area. The mass transfer coefficient within the dispersed drops is determined from a rigid sphere model by taking into account the residence time distribution of drops, and the coefficient around the drops is calculated by Ranz-Marshall's correlation with the terminal settling velocity of a rigid sphere. The interfacial area of dispersed drops is calculated by the use of correlations for the drop diameter and the holdup of dispersed phase in the mixer-settler extraction column. The calculated results for the separation of samarium and gadolinium with a five-stage mixer-settler extraction column are compared with the experimental results at various agitation speeds and flow ratios between two phases. The extraction behavior in the multistage column is explained by a model based on the hydrodynamics and the mass transfer within the mixer. Effects of the pH value in aqueous phase, the extractant concentration in organic phase and the number of stages on the extraction behavior in the mixer-settler column are also shown.     

Experimental mass transfer coefficients in a pilot plant multistage column extractor

The volumetric overall mass transfer coefficients in a multistage column have been measured using axial dispersion model for toluene–acetone–water system. The effect of operating parameters on the volumetric overall mass transfer coefficients has been investigated for both mass transfer directions. The results show that the mass transfer performance is strongly dependent on rotor speed and mass transfer direction, although only slightly dependent on phase flow rates. In addition, empirical correlations to predict the overall mass transfer coefficients have been developed. The proposed correlations based on dimensionless numbers can be considered as a useful tool for the possible scale up of the multistage column extractor.     

Using in-line static mixers to intensify gas-liquid mass transfer processes

A novel static mixer design (screen-type elements) capable of taking advantage of the interfacial characteristics of industrial gas/liquid systems was developed. The interfacial area of contact, and volumetric oxygen transfer coefficient, were investigated using a 25.4 mm pipe loop in which liquid superficial velocities of up to 2.0 m/s (and gas holdups as high as 0.15) were tested. Volumetric mass transfer coefficients as high as were achieved. The ability of this design to achieve high energy utilization efficiencies is validated by achieving oxygen transfer rate as high as 4.2 kg/kWh in the presence of surfactants.Depending on the process requirements and the interfacial properties of the system, high volumetric oxygen transfer coefficients or high energy utilization efficiencies can be achieved by modifying the contactor design and/or operating conditions.     

Use of axial dispersion and plug flow models for determination of axial mixing and mass transfer coefficient in an l‐shaped pulsed packed extraction column

In this study, the volumetric overall mass transfer and phases axial mixing coefficients have been investigated in a pilot plant of an L‐shaped pulsed packed extraction column by using two liquid systems of toluene/acetone/water and n‐butyl/acetone/water. The mass transfer performance has been evaluated using two methods of axial dispersion and a plug flow model. The effect of the operational variables and physical properties, including the dispersed and continuous phases flow rates, pulsation intensity, and interfacial tension, on mass transfer and phases axial mixing coefficients have been considered. It has been found that the pulsation intensity and the continuous phase flow rate seriously affect the mass transfer coefficient, however, the dispersed phase flow rate has a weaker effect. Also, the axial mixing of a phase is strongly affected by the pulsation intensity and the flow rate of the phase itself and it is not affected by the second phase flow rate. Finally, new correlations are proposed to accurately predict the mass transfer and axial mixing coefficients.     

Impact of mass transfer coefficient correlations on prediction of reactive distillation column behaviour

A significant part of the safety analysis of a reactive distillation column is the identification of multiple steady states and their stability. A reliable prediction of multiple steady states in a reactive distillation column is influenced by the selection of an adequate mathematical model.For modelling reactive distillation columns, equilibrium (EQ) and nonequilibrium (NEQ) models are available in the literature. The accuracy of the nonequilibrium stage model seems to be limited mainly by the accuracy of the correlations used to estimate the mass transfer coefficient and interfacial area.The binary mass transfer coefficients obtained from empirical correlations are functions of the tray design and layout, or of the packing type and size, as well as of the operational conditions and physical properties of the vapour and liquid mixtures.In this contribution, the nonequilibrium model was used for the simulation of a reactive distillation column. For prediction of the binary mass transfer coefficient for a sieve tray, four correlations were chosen to show their impact on the prediction of the reactive distillation column behaviour. As a model reactive distillation system, the synthesis of methyl tertiary-butyl ether (MTBE) was chosen. The steady-state analysis and the dynamic simulation of the model system were done. Qualitative differences between the steady states were predicted using the chosen correlations.     

Surface-tension-induced interfacial convection and its effect on rates of mass transfer

Surface-tension-induced interfacial convection (Marangoni phenomena) can appear as a result of mass and heat transfer, compression and dilatation of surface films or their non-Newtonian behaviour and owing to presence in the interface of electrostatic charges. In process engineering problems the mass transfer effect is usually predominant and, depending on the geometry of the system, leads to surface renewal or changes in interfacial area. The surface renewal phenomena can appear as instabilities or disturbances and their effect on mass transfer is presented for transfer to and from drops as well as across flat interfaces in stirred and laminar flow contactors. Mass transfer coefficients and drag coefficients of drops are compared under conditions of undisturbed (diffusional) transfer, cellular convection and interfacial turbulence for stable and unstable direction of transfer. The importance of gravitational instability is indicated.     

Chemisorption of CO2 in a gas–liquid vortex reactor: An interphase mass transfer efficiency assessment

To develop cost-effective CO₂ capture technology process intensification will play a vital role. In this work, the capabilities of a gas–liquid vortex reactor (GLVR) as novel process intensification equipment are evaluated by studying its interphase mass transfer parameters to build up the fundamentals for its future application to for example, CO₂ capture. The NaOH-CO₂ chemisorption system and Danckwerts' model are applied to obtain the effective interfacial area and liquid-side mass transfer coefficient. Results show that the gas–liquid contact in the GLVR is capable of both generating a large interfacial area in a small reactor volume and creating a region with high-energy dissipation to improve mass transfer. A comparison of the volumetric mass transfer coefficients with data reported in literature for conventional and intensified reactor types confirms a superior mass transfer efficiency and, most importantly, a favorable energetic efficiency of the GLVR.     

Steady-state mass transfer between two opposite discs and a liquid in radial divergent flow

The paper deals with global and local mass transfer between a liquid and two opposite fixed discs. The liquid is introduced through a central hole in one of the discs and flows radially. The mass transfer coefficients, measured by the electrochemical method, are empirically correlated. The correlations are compared with corresponding empirical correlations from the literature. Local measurements using microelectrodes allowed to determine the evolution of the local mass transfer coefficients over each disc as a function of the geometrical parameters, particularly the gap between the discs.     

Modeling the axial distribution of mass transfer coefficient in an agitated-pulsed extraction column

The dispersed phase holdup and drop size in solvent extraction columns vary along the column height and this affects the mass transfer coefficient and interfacial area. In this article, mass transfer study was performed experimentally using a 25 mm diameter agitated pulsed column. The axial distribution of mass transfer coefficient was determined by coupling population balance equation and axial dispersion model by taking the longitudinal variation in hydrodynamic performance into consideration. Feasibility of different mass transfer models in predicting concentration profiles was evaluated and a novel correlation based on effective diffusivity was developed. The results showed that both overall and volumetric mass transfer coefficients have significant change along the column height and greatly depends on the agitation speed and pulsation intensity. Increasing dispersed phase velocity also augments the overall mass transfer coefficient. The maximum number of transfer unit was measured to be 10 m⁻¹ at agitation speed of 1000 rpm.     

Vaporization characteristics of heavy metal compounds at elevated temperatures

Volatilities and conversions of heavy metal compounds under oxidation conditions at elevated temperatures up to 1,000°C are analyzed using a thermogravimetric furnace to evaluate their behaviors in an incinerator. Most pure metals and their oxides are relatively stable without releasing metal substances into the atmosphere, except for several metals such as As and Hg. However, some chlorides are vaporized in the combustion temperatures and for these volatile chlorides, vaporization fluxes are obtained based on the measurement of their weight losses with increasing temperatures in the furnace. Experimental vaporization fluxes are compared to maximum theoretical fluxes from Herz-Knudsen’s kinetic theory of gas. Results of comparison show that evaporation coefficient, α, for each volatile heavy metal compound appears to be a characteristic value of the evaporating substance, not varying with increasing temperatures and the obtained coefficients are ranged in 10^-6 to 10⁸, which could be explained by a vaporization-condensation model of liquids. With some theoretical consideration on interfacial resistance, mass transfer coefficients, K_c for evaporation, are determined as a function of absolute temperatures, and ranged in 10-6 to 10^-7.     

Mathematical model and analysis of PMMA solution processes

A mathematical model of reactors for the polymerization of methylmethacrylate (MMA) has been developed and analyzed in order to better understand the reactor dynamics and to determine conditions for improved operation. The exploration of the effect of heat transfer in an MMA polymerization reactor system has been conducted by the development of a detailed model. Two correlations for the overall heat transfer coefficient have been used to study the effect of heat transfer. The heat transfer coefficient estimated by an empirical correlation (Kravaris) is only a function of conversion. Due to its simplicity, it may not express very well the true heat transfer phenomena. But in Henderson’s correlation, it is related to the viscosity of the reaction mixture, which in turn depends on the reaction temperature and volume fraction of each species in the reactor. The steady state solutions of mass and energy balances in the reactor depend on the nature of the heat transfer correlation, as does the number of isola branches. Henderson’s correlation may be preferred to calculate the dynamics of the PMMA reactors. The addition of jacket dynamics to the system results in no isola solution branches and no Hopf bifurcations.