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.     

Desulfurization in the gas-continuous impinging stream gas-liquid reactor

An investigation is made to evaluate the flue gas desulfurization (FGD) by absorption in a gas-continuous impinging stream gas-liquid reactor recently developed for systems involving fast reaction(s) in liquid. The mixture of air and SO₂ was used as the pseudo-flue gas and Ca(OH)₂-water suspension as the absorbent. By employing horizontal two-impinging streams, the reactor is simple in structure with few internal parts, while exhibits satisfied overall performance for FGD. Under moderate conditions, the content of SO₂ in the cleaned gas can achieve a level much lower than that permitted, while the pressure drop across the device is about 400 Pa only. The influences of some operating and structural parameters, such as V_L/V_G, Ca/S mole ratio, SO₂ concentration in flue gas, impinging distance S, and nozzle location, etc., are examined. The gas-film mass transfer coefficient, k_G, is determined based on Sauter mean diameter of spray droplets. The results show that k_G is essentially independent of concentration of SO₂ in flue gas, implying the process can be considered to be controlled by diffusion through gas film. The relationship between k_G and impinging velocity, u₀, is fitted to be with the standard deviation of , suggesting u₀ is a strong effecting variable on mass transfer, and, consequentially, important operating variable. In the range of u₀ from 5.53 to , the values determined for the volumetric mass transfer coefficient, k_Ga, are 0.577-, and those for k_G are ranged from 0.00641 to .     

Dynamics of spiral bubble plume motion in the entrance region of bubble columns and three-phase fluidized beds using 3D ECT

In this study, we have developed, for the first time in the field, a ‘dynamic’ three-dimensional image reconstruction technique for electrical capacitance tomography (ECT) imaging based on a neural-network multi-criterion optimization (NNMOIRT). This development enables a real time, 3D imaging of a moving object to be realized. The image reconstruction scheme of the 3D ECT is established by introducing a 3D sensitivity matrix into the NN-MOIRT algorithm, developed earlier by the authors. The sensitivity matrices employed are based on 6- and 12-electrode twin-plane cylindrical sensors. The NN-MOIRT algorithm reconstructs simultaneously the image voxels (volume pixels) on 20×20×20 resolutions from the capacitance data obtained using the twin-plane sensors which surrounds the 3D section of 8 cm in length in the cylindrical columns. The technique is successfully tested over a 3D simulated as well as actual experimental objects. The 3D ECT technique is used to investigate the transient phenomena in the entrance region of a 10 cm diameter column using a single nozzle gas distributor with paraffin liquid (Norpar), air, and glass-beads as flow media. Hydrodynamic characteristics of the gas-liquid and gas-liquid-solid flows, including 3D bubble plume spiral motion, 3D large scale liquid vortex dynamics and real time three-dimensional gas holdup distribution are studied.     

Solids flow mapping in a high pressure slurry bubble column

Successful design and scale-up of Slurry Bubble Column Reactors (SBCRs) require proper understanding of how operating conditions affect their flow behavior. Presently, there is little information on the flow dynamics of solids (e.g., distribution of velocities and turbulent parameters) in slurry systems that are operated at industrially relevant conditions of high pressure, high superficial gas velocities, and high solids loading.Computer Automated Radio Particle Tracking (CARPT) is widely recognized as one of a few techniques that can be reliably used even in highly turbulent and opaque slurry flows. This work utilizes an improved CARPT technique to investigate the effect of reactor pressure (0.1-1 MPa) and superficial gas velocity (0.08-0.45 m/s) on solids phase velocity and shear stress in a pilot scale 0.16 m diameter stainless steel column using an air-water-glass beads () system. The solids axial velocity and shear stress were found to increase noticeably with pressure and superficial gas velocity in the churn turbulent flow regime.     

Solids mixing in the riser of a circulating fluidized bed

Gas/solid and catalytic gas phase reactions in CFBs use different operating conditions, with a strict control of the solids residence time and limited back-mixing only essential in the latter applications. Since conversion proceeds with residence time, this residence time is an essential parameter in reactor modelling. To determine the residence time and its distribution (RTD), previous studies used either stimulus response or single tracer particle studies.The experiments of the present research were conducted at ambient conditions and combine both stimulus response and particle tracking measurements. Positron emission particle tracking (PEPT) continuously tracks individual radioactive tracer particles, thus yielding data on particle movement in “real time”, defining particle velocities and population density plots.Pulse tracer injection measurements of the RTD were performed in a 0.1 m I.D. riser. PEPT experiments were performed in a small ( I.D.) riser, using ¹⁸F-labelled sand and radish seed. The operating conditions varied from 1 to 10 m/s as superficial velocity, and 25- as solids circulation rate.Experimental results were compared with fittings from several models. Although the model evaluation shows that the residence time distribution (RTD) of the experiments shifts from near plug flow to perfect mixing (when the solids circulation rate decreases), none of the models fits the experimental results over the broad (U,G)-range.The particle slip velocity was found to be considerably below the theoretical value in core/annulus flow (due to cluster formation), but to be equal at high values of the solids circulation rate and superficial gas velocity.The transition from mixed to plug flow was further examined. At velocities near U_tr the CFB-regime is either not fully developed and/or mixing occurs even at high solids circulation rates. This indicates the necessity of working at U> approx. ( to have a stable solids circulation, irrespective of the need to operate in either mixed or plug flow mode. At velocities above this limit, plug flow is achieved when the solids circulation rate . Solids back-mixing occurs at lower G and the operating mode can be described by the core/annulus approach. The relative sizes of core and annulus, as well as the downward particle velocity in the annulus (∼U_t) are defined from PEPT measurements.Own and literature data were finally combined in a core/annulus vs. plug flow diagram. These limits of working conditions were developed from experiments at ambient conditions. Since commercial CFB reactors normally operate at a higher temperature and/or pressure, gas properties such as density and viscosity will be different and possibly influence the gas-solid flow and mixing. Further tests at higher temperatures and pressures are needed or scaling laws must be considered. At ambient conditions, reactors requiring pure plug flow must operate at and . If back-mixing is required, as in gas/solid reactors, operation at and is recommended.     

Gas-liquid mass transfer in a circulating jet-loop nitrifying MBR

Based on airlift configuration, a novel circulating jet-loop submerged membrane bioreactor (JLMBR) adapted to ammonium partial oxidation has been developed. Membrane technology and combined air and water forced circulation are adopted to obtain a high biomass retention time and to achieve a separate control of mixing and aeration. This study is intended to determine how gas-liquid mass transfer is affected by operating conditions. In a first approximation, liquid was assumed to be perfectly mixed. A classical non-steady state clean water test, known as the “gas out-gas in” method, was used to determine the gas-liquid mass transfer coefficient k_La. Air and recirculated liquid superficial velocities were gradually increased from 0.013 to and 0.0056 to , respectively. Subsequently, the gas-liquid mass transfer coefficient k_La varied from 0.01 to . It appears to be influenced by the combined action of air and recirculated liquid flowrates in the range and , respectively, for air and liquid. Correlations are proposed to describe this double influence. Experiments were performed on tap water and a culture medium used for the autotrophic growth of nitrifying bacteria, respectively. Oxygen transfer appeared to be not significantly affected by the mineral salt encountered in this medium.     

Flow regimes and gas holdup in paper pulp-water-gas three-phase slurry flow

Hydrodynamic flow characteristics of solid-liquid-gas slurry made by intimately mixing fibrous paper pulp with water and air were investigated in a short, vertical circular column. The pulp consistency (weight fraction of pulp in the pulp-water mixture) was varied in the low consistency range of 0.0-1.5%. The test section was long, with inner diameter. Mixing of the slurry prior to entering the test section was done using a patented mixer with controlled cavitation that generated finely dispersed micro-bubbles.Flow structures, gas holdup, and the geometric and population characteristics of gas bubbles in the gas-pulp-liquid three-phase flow were experimentally investigated, using visual observation, Gamma-ray densitometry, and flash X-ray photography. Superficial velocities of the gas and liquid/pulp mixture covered the ranges 0- and 21-, respectively.Five distinct flow regimes could be visually identified. These included dispersed bubbly, characterized by isolated micro-bubbles entrapped in fiber networks; layered bubbly, characterized by bubbles rising in a low consistency annular zone near the channel wall; plug; churn-turbulent; and slug. The dispersed and layered bubbly regimes could be maintained only at very low gas superficial velocities or gas holdups. Flow regime maps were constructed using phasic superficial velocities as coordinates, and the regime transition lines were found to be sensitive to consistency.The cross section-average gas holdup data showed that both the dispersed and the layered bubbly regimes could best be represented by the homogeneous mixture model. The drift flux model could best be applied to the reminder of the data when the plug and churn-turbulent flow regimes were treated together, and the slug flow was treated separately. The drift flux parameters depended on the pulp consistency.     

Particle dispersion in viscous three-phase inverse fluidized beds

Dispersion characteristics of low density fluidized particles such as polyethylene and polypropylene were investigated by using the stochastic method in three-phase inverse fluidized beds with viscous liquid medium ( in height). To establish the relationship between the pressure drop variation and the particle dispersion in test section, the histogram of pressure drop fluctuations were also measured and analyzed. Effects of operating variables such as gas and liquid velocities, liquid viscosity and media particle kind (density) on the fluctuating frequency, dispersion coefficient and exiting rate of media particles from the test section were determined. The fluctuating frequency and dispersion coefficient of particles increased with increasing gas or liquid velocity, but decreased considerably with increasing liquid viscosity in three-phase inverse fluidized beds. The dispersion coefficient of media particles of relatively higher density exhibited a value higher than that of lower density particles. The dispersion coefficients of particles were well correlated with operating variables in terms of dimensionless groups.     

Trickle-bed CFD studies in the catalytic wet oxidation of phenolic acids

An Euler-Euler computational fluid model was developed successfully for the hydrodynamic prediction of a trickle-bed reactor (TBR) designed for advanced wastewater treatment facilities. Catalytic wet air oxidation of phenolic acids was simulated in a TBR by means of computational fluid dynamic (CFD) in the temperature range and pressures . The hydrodynamic model validation was accomplished through the comparison of simulated pressure drop and liquid holdup with experimental data from the literature. In a broad range of gas and liquid flows studied (G=0.10-0.70 and ) at different operation conditions, CFD demonstrated the considerable effect of operating pressure in pressure drop, whereas a minor influence was detected for the liquid holdup. CFD runs were then performed for the catalytic wet air oxidation of aqueous phenolic acids solution. The reactor behaviour was analysed by means of total organic carbon profiles which reflected the influence of temperature, pressure, gas-liquid flows and initial pollutant concentration.     

Measurement of local specific interfacial area in bubble columns via a non-isokinetic withdrawal method coupled to electro-optical detector

Precise measurement of gas-liquid interfacial surface area is essential to reactor design and operation. Mass transfer from the gas phase to the liquid phase is often a key feature that controls the overall process. Measurement of gas-liquid interfacial area is often made through a separate measurement of the gas holdup and bubble size with complex and/or sophisticated methods. In this work, an inexpensive method is presented for the simultaneous determination of both local gas holdup and bubble diameter. The method is based on the withdrawal of the air-liquid dispersion under non-isokinetic conditions and on bubble counting via a simple optical device. The method was calibrated in a bubble column with several withdrawal pressures using coalescing and non-coalescing media. During the same calibration experiment, gas holdup was also measured manometrically and individual bubble diameters were measured by a photographic method. With a vacuum pressure of 3 kPa, local interfacial area measured with the withdrawal method produced a relative error below 13%, compared to the manometric/photographic method. The method was then used to characterize local specific interfacial area in a bubble column under several operating conditions with coalescing and non-coalescing media. In coalescing media and with superficial gas velocities (v_g) from 0.25 to 3.5 cm/s, the average interfacial area ranged from 17 to . With non-coalescing media the average interfacial area ranged from 40 to . Under the test condition it was observed that gas holdup is a parameter that has a greater distribution (standard deviation from 30% to 70%) than the volume-mean bubble diameter (standard deviation from 6% to 12%). It is shown that a model previously developed for characterizing gas holdup homogeneity is also suitable for characterizing interfacial area homogeneity.     

Levitation of air bubbles and slugs in liquids under low-frequency vibration excitement

This experimental study reports the influence of low-frequency vibrations, in the range of 60-400 Hz, on the rise of single air bubbles and slugs injected into two columns (of diameters 0.014 and 0.05 m), filled with liquids of varying densities (in the range 889- and viscosities (in the range 0.48-1.4 Pa s). For a specified set of operating conditions the bubbles or slugs can be made to levitate, i.e. held stationary in the column. The height of the liquid, h, above the position at which the gas bubble is levitated was determined for a wide range of operating conditions (vibration frequency and amplitude, operating pressure, column diameter, liquid density and viscosity). The experimentally determined values of h are in good agreement with the theoretical model of Baird [1963a. Resonant bubbles in a vertically vibrating column. Canadian Journal of Chemical Engineering 41, 52-55].     

A greener, pressure intensified propylene epoxidation process with facile product separation

A novel biphasic process concept for the synthesis of propylene oxide (PO) from propylene is presented, using the long known catalyst, methyl trioxorhenium and aqueous hydrogen peroxide as the oxidant. Propylene is fed as gas, which is transported to the liquid phase containing the oxidant, catalyst and methanol as a cosolvent that improves propylene solubility. The selective oxidation produces PO which is distilled easily from the liquid phase taking advantage of the relatively low normal boiling point of PO compared to those of methanol and water. The process satisfies the sustainability principles of waste minimization, use of benign reagents and process intensification at mild conditions. The process produces PO in yields exceeding 98%. It operates at essentially ambient temperature and moderate pressures , using easily recyclable, low hazard aqueous methanol, as solvent. The catalyst, methyl trioxorhenium, is robust under the operating conditions. A key aspect of the innovation is the use of nitrogen gas pressure to enhance propylene availability in the liquid phase increasing its conversion from ∼80% (without N₂) to complete (with N₂) in a few hours. These findings pave the way for catalyst durability and recycle studies, aimed at demonstrating a continuous process that is economically and environmentally sustainable compared to existing processes.     

Oxygen transfer prediction in aeration tanks using CFD

In order to optimize aeration in the activated sludge processes, an experimentally validated numerical tool, based on computational fluid dynamics and able to predict flow and oxygen transfer characteristics in aeration tanks equipped with fine bubble diffusers and axial slow speed mixers, is proposed. For four different aeration tanks (1;1493;8191 and ), this tool allows to precisely reproduce experimental results in terms of axial liquid velocities, local gas hold-ups. Predicted oxygen transfer coefficients are within ±5% of experimental results for different operating conditions (varying pumping flow rates of the mixers and air flow rates). The actual bubble size must be known with precision in order to have a reliable estimation of the oxygen transfer coefficients.     

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.     

Application of the off-gas method to the measurement of oxygen transfer in biofilters

To determine the oxygen mass transfer in clean water in biofilters, a method based on the follow up of the oxygen fraction in the off gas during the oxidation of sulphite in excess has been evaluated and applied to a pilot-scale unit (250 L, superficial gas velocity from 0 to , superficial liquid velocity from 0 to ). Tests performed on a two-phase reactor showed that, without any cobalt addition, standard oxygen transfer efficiencies (SOTE) obtained from the proposed method are not statistically different from those issued from the standardised method. A relationship has been proposed to express SOTE values as a function of the conductivity, and the influence of the gas and liquid velocities on SOTE and k_La has been investigated.     

Gas hold-up, mixing time and gas-liquid volumetric mass transfer coefficient of various multiple-impeller configurations: Rushton turbine, pitched blade and techmix impeller and their combinations

Gas hold-up, mixing intensity of dispersion characterised by exchange flows between adjacent impellers and a volumetric mass transfer coefficient are presented for 18 impeller configurations in triple-impeller vessel of inner diameter . Rushton Turbines, six Pitched Blade impellers pumping down and hydrofoil impellers Techmix 335 (Techmix co., Czech republic) pumping up or down and their combinations were used. aqueous solution was used as a liquid phase, which represents non-coalescent batches. Gas hold-ups and volumetric mass transfer coefficients are presented for individual configurations as functions of specific power dissipated and superficial gas velocity. The regression of the mass transfer coefficients shows large standard deviation (30%). The power number included to the regression to express the impeller configuration effect did not improve the standard deviation significantly (23%). The impeller configurations with low power number (less than unity) provide higher dispersion mixing intensities, while the impeller configurations with high power number provide better mass transfer performance.     

External-loop fluidized bed airlift bioreactor (EFBAB) for the cometabolic biotransformation of 4-chlorophenol (4-cp) in the presence of phenol

The advantages from a 4-l external-loop inversed fluidized bed airlift bioreactor (EIFBAB) reported by Loh and Liu [2001. Chemical Engineering Science 56, 6171-6176] was synergized with preferential adsorption by granular activated carbon (GAC) for the enhanced cometabolic biotransformation of 4-chlorophenol (4-cp) in the presence of phenol as a growth substrate. This was achieved by incorporating a GAC fluidized bed in the lower part of the riser with the gas sparger relocated above this fluidized bed to avoid the presence of a 3-phase flow in the fluidized bed consequently providing larger gas holdup. Expanded polystyrene beads (EPS) were used as the supporting matrix for immobilizing Pseudomonas putida ATCC 49451, in the downcomer of the bioreactor. The hydrodynamics of the bioreactor system was characterized by studying the effect of the extent of valve opening, under cell-free condition, on gas holdup and liquid circulation velocity at different gas velocities and solids loading (EPS and GAC). The experimental data for gas holdup were modeled using power law correlations, while a Langmuir-Hinshelwood kinetics model was used for the liquid circulation velocity. The bioreactor was tested for batch cometabolic biotransformation of 4-cp in the presence of phenol at various concentration ratios of phenol and 4-cp (ranging from phenol: 4-cp to phenol: 4-cp) at 9% EPS loading and 2.8% (10 g) GAC loading. The 4-cp and phenol biotransformations were achieved successfully in the bioreactor system, which ascertained the feasibility of the bioreactor. Biotransformation of high 4-cp and phenol concentrations, which was oxygen limited, was also effectively achieved by increasing the gas holdup in the riser. This was possible in the current EFBAB system because of the synergistic effect of the GAC fluidized bed, the globe valve and cell immobilization by EPS.     

Static mixers with a gas continuous phase

The aim of this work was to characterise hydrodynamics and mass transfer in a gas-liquid contactor containing static mixers (SMs). The originality of this study lies in the fact that these mixing organs are used with a gas continuous phase. Two types of SM were implemented in co-current flows, Statiflo and Lightnin. The pressure drop ΔP, the volumic interfacial area a and the volumic mass transfer coefficient k_La were measured in several configurations: horizontal flow, vertical up-flow and vertical down-flow. The influences of position and flow rates were studied in order to understand the behaviour of these contactors, and to optimise the operating conditions. As expected, the pressure drop was found to increase mainly with gas velocity but also with liquid velocity, and to reach 3300 Pa in the range of velocities studied (the gas flow rate varied between 4 and and the liquid flow rate between 0 and 100 L/h), far less than Sülzer SM. The volumic interfacial area and the volumic mass transfer coefficient showed the same changes, a varying between 100 and , and k_La reaching 0.07 L/s. This is interesting compared with other classical absorption processes: indeed, even if packing towers can provide the same range of values, the operating conditions are more drastic or the dimensions of the apparatuses are far larger than SM ones. The position was also found to have an influence on the hydrodynamic and mass transfer parameters (ΔP, a and k_La).