Measurement of mass transfer coefficient in an airlift reactor with internal loop using coalescent and non‐coalescent liquid media

In this work the sulfite oxidation (SOM), dynamic pressure‐step (DPM) and gassing‐out (GOM) methods were compared for volumetric mass transfer coefficient measurement in an airlift reactor with internal loop. As a liquid phase both, non‐coalescent and coalescent media were used. Among the methods discussed here, the mass transfer coefficient (k_La) values obtained by the DPM appear as the most reliable as they were found to be independent of oxygen concentration in the inlet gas, which confirmed the physical correctness of this method. The difference between data measured using air and oxygen was not higher than 10%, which was comparable to the scatter of experimental data. It has been found that the sulfite oxidation method yielded k_La values only a little higher than those obtained by the DPM and the difference did not exceed 10%. Up to an inlet gas velocity (U_GC) of ?0.03 m s^?1 the GOM using oxygen as a gas medium gave k_La values in fact identical with those obtained by the DPM. At higher flows of the inlet gas, the GOM yielded k_La values as much as 15% lower. The enhancement in oxygen mass transfer rate determined in non‐coalescent media was estimated to be up to +15%, when compared with a coalescent batch. The experimental dependence of k_La vs the overall gas hold‐up was described by an empirical correlation. 1 Copyright © 2004 Society of Chemical Industry     

Improved power and mass transfer correlations for design and scale-up of multi-impeller gas-liquid contactors

The impeller power and volumetric mass transfer coefficient were measured in a pilot-plant single-, double- and triple-impeller vessels of inner diameter 0.6 m. The experimental conditions corresponded with those used earlier in geometrically similar laboratory scale vessel of inner diameter 0.29 m [Fujasová et al., 2007, Chem. Eng. Sci. 62, 1650-1669]. The same impeller types and their combinations were used as well as the experimental techniques and forms of the data treatment/correlations, which distinguish bottom and upper section behaviour. Concretely, 23 combinations of the following impeller types were used: Rushton turbine (RT), six-pitched-blade impeller pumping upwards (PBU) and downwards (PBD), Lightnin A315 (LTN) impeller, and Techmix 335 pumping upwards (TXU) and downwards (TXD). Distilled water, representing a low-viscosity coalescent batch, was used as the liquid phase.It was found that the correlations established on the basis of the laboratory scale data might be used to describe the transport characteristics in the pilot-plant vessel. The more precise correlations, based on the data from both the laboratory and the pilot-plant scale vessels have also been established. The specific powers dissipated by impellers under gassed conditions (P_g) were within the interval from 10 to 8500 W m⁻³ in the experiments. General correlations of the relative power down under aeration (P_g/P₀) are presented separately for the bottom and upper sections of the vessel. k_La were measured by dynamic pressure method in the individual vessel sections simultaneously. Their values moved within the interval from 0.002 to 0.21 s⁻¹. The best fit provided correlating the single- and the multi-impeller (double and triple) vessels data separately. Correlation of the k_La data measured in the middle height of the triple-impeller vessel, the method often used in literature, is also included.Of the triple-impeller configurations, 3RT gave the best mass transfer performance. The configurations utilizing the same impeller type have shown that the radial flow impellers provide higher (20 up to 50%) mass transfer coefficients than the axial flow impellers. The combined configurations (i.e., those with an RT impeller in the bottom section) do not achieve the mass transfer performance of 3RT. The k_La values produced by RT+2PBD and RT+2PBU were only 15-20% lower than those achieved using 3RT at the same power input. The 3LTN and RT+2LTN configurations provided the poorest mass transfer coefficients at the same power input, both being up to 40% lower than those of 3RT.     

Volumetric mass transfer coefficients in an internal loop airlift reactor with low‐density particles

The influence of organic additives (propanol, benzoic acid, isoamyl alcohol and carboxymethylcellulose) on the volumetric mass transfer coefficient, k_La, in an internal loop airlift reactor with low‐density particles (nylon‐6 and polystyrene) was investigated. The k_La values increased with increase in superficial gas velocity, U_sg, and decreased with increase in solid loading. A draft tube to reactor diameter ratio, D_R/D, of 0.4 gave maximum k_La values. The addition of benzoic acid and propanol increased the k_La values owing to their coalescence inhibiting characteristics. The addition of isoamyl alcohol decreased k_La, owing to the formation of rigid bubbles and recirculation of small bubbles having a low oxygen content. The k_La values decreased with increase in the concentration of the non‐Newtonian fluid carboxymethylcellulose (CMC). The proposed correlations predicted the experimental data well. Copyright © 2006 Society of Chemical Industry     

Estimation of kLa Values in Bench‐Scale Stirred Tank Reactors with Self‐Inducing Impeller by Multiphase CFD Simulations

A multiphase computational fluid dynamics (CFD) simulation methodology is developed and proposed for the estimation of the spatial distribution of k_La values in a bench‐scale reactor equipped with a self‐inducing impeller. The importance of estimating an apparent drag coefficient, which considers the effect of turbulence on the gas bubble rising velocity, is also tackled by applying different correlations available in literature, namely, Brucato, modified Brucato, and Pinelli correlations. The spatial distribution of k_La values in the agitated vessel is found from the CFD results using Danckwert's surface renewal model. An analysis of the gas volume fraction distribution obtained from the simulations is performed in order to choose the most suitable drag model. The modified Brucato correction correlation for the drag force exhibits the best agreement with experimental data.     

Interfacial Area and Liquid‐Side Volumetric Mass Transfer Coefficient in a Downflow Bubble Column

An experimental investigation was made to measure interfacial area, a, and liquid‐side volumetric mass transfer coefficient, k_La, in a downflow bubble column by chemical methods viz., absorbing CO₂ in aqueous sodium hydroxide and sodium carbonate/bicarbonate buffer solution respectively. The effect of gas and liquid flowrate and nozzle sizes on a and k_La were investigated. The experimental data obtained in the present system were analyzed and correlations were developed to predict a and k_La in terms of superficial gas velocity. The variation of a and k_La with specific power input were shown in graphical plot and compared with other gas‐liquid systems.     

Power Input Prediction in Agitated Gas‐Liquid Contactors with Non‐coalescent Batch

Volumetric mass transfer coefficients, k_La, just as power input are considered as essential parameters for mechanically agitated gas‐liquid contactors in relation to their optimization and design. The knowledge of power input is crucial for the prediction of other mass transfer characteristics. A power input correlation is created for the industrial design of the process with a non‐coalescent batch that would be appropriate for a broad range of operational conditions. The recommended resulting correlation is able to predict the power input for impellers in industrial‐scale design for a significant scope of operational conditions.     

Mass transfer properties of bubble columns suspending immobilized glucose oxidase gel beads for gluconic acid production

The volumetric gas-liquid oxygen transfer coefficient, k_L a, and the liquid–solid coefficient, k_S, were measured in a 6.7 L external loop airlift bubble column (ELBC), a 2.5 L internal loop airlift (ILBC) and a 2.5 L normal bubble column (NBC) by the steady state method proposed previously using the oxidation of glucose with air catalyzed by glucose oxidase, GO. For an improved and simultaneous determination of k_L a and k_S, GO was entrapped in calcium alginate gel beads together with fine palladium particles instead of catalase to decompose the hydrogen peroxide produced. The gas holdup, ?_G, in each type of bubble column and the liquid circulation velocity, u_L, governing ?_G in the ELBC were also measured to correlate the data on k_La according to the previous correlations proposed for a larger scale of the ELBC, ILBC and NBC. The data on k_L a, k_S, ?_G and u_L (only for the ELBC) in the reaction system were compared to each other for the three types of bubble columns. The results are well predicted by the previous correlations.     

Mass Transfer Characteristics of Syngas Components in Slurry System at Industrial Conditions

The gas‐liquid mass transfer behavior of syngas components, H₂ and CO, has been studied in a three‐phase bubble column reactor at industrial conditions. The influences of the main operating conditions, such as temperature, pressure, superficial gas velocity and solid concentration, have been studied systematically. The volumetric liquid‐side mass transfer coefficient k_La is obtained by measuring the dissolution rate of H₂ and CO. The gas holdup and the bubble size distribution in the reactor are measured by an optical fiber technique, the specific gas‐liquid interfacial area aand the liquid‐side mass transfer coefficient k_L are calculated based on the experimental measurements. Empirical correlations are proposed to predict k_L and a values for H₂ and CO in liquid paraffin/solid particles slurry bubble column reactors.     

Statistical assessment of gas/liquid mass transfer in slurry-phase propylene polymerization process

A statistical approach was developed to investigate the effects of pressure, temperature, mixing speed and solid concentration on k_La for gaseous hydrogen, ethylene, and propylene in liquid n-hexane containing solid polypropylene powder in a 4-litre agitated reactor. The solubilities of the gases appeared to follow Henry's Law. Statistical correlations to predict k_La were proposed and response surfaces were constructed. k_La values appeared to reach a maximum around 15 mass% and sharply decrease above 30 mass%. The effects of pressure and temperature on k_La were found to depend on the gas-liquid system and operating conditions used.     

Improving k La determination in fungal fermentation,taking into account electrode response time

An alternative way for determining the oxygen mass transfer coefficient, k_La, based upon the traditional dynamic method, is proposed. The oxygen material balance equation in the liquid phase is integrated after insertion of the oxygen probe response time (first order type), and k_La values are determined by employing Marquardt's algorithm, considering as a weighting factor the model's sensitivity with respect to k_La. Bench‐scale fermentations of Aspergillus awamori, performed under different agitation (300–700 rpm) and aeration conditions (0.2–0.6 vvm), were utilized for calculating k_La values (0.0283–0.0874 s⁻¹), employing three methods: two so‐called traditional, the gas balancing and the dynamic methods, and the one proposed here. The latter method is shown to be as reliable as the aforementioned methods but is easier to apply when the oxygen level in the reactor is above the critical value. © 2000 Society of Chemical Industry     

Effect of ultrasonic waveforms on gas–liquid mass transfer in microreactors

This study aims to investigate the effect of ultrasonic waveforms on the gas–liquid mass transfer process. For a given load power (P), continuous rectangular wave yielded stronger bubble oscillation and higher mass transfer coefficient (k_La) than continuous triangular and sinusoidal wave. For pulsed ultrasound, the k_La decreased monotonically with decreasing duty ratio (D), resulting in weak enhancement at low D (≤33%). For a given average load power (P_A), concentrating the P for a shorter period resulted in a higher k_La due to stronger cavitation behavior. For a given P_A and D, decreasing the pulse period (T) led to an increase in k_La, which reached a constant high level when the T fell below a critical value. By optimizing the D and T, a k_La equivalent to 92% of that under continuous ultrasound was obtained under pulsed ultrasound at a D of 67%, saving 33% in power consumption.     

Semi‐theoretical prediction of volumetric mass transfer coefficients in bubble columns with organic liquids at ambient and elevated temperatures

A semi‐theoretical approach for predicting k_La values (referred to liquid volume) in 18 organic liquids [acetone, aniline, 1‐butanol, benzene, cyclohexane, decalin, 1,2‐dichloroethane, 1,4‐dioxane, ethanol (96%), ethylacetate, ethylbenzene, ligroin, methanol, nitrobenzene, 2‐propanol, tetralin, toluene, and xylene] at various operating conditions (including elevated temperatures and pressures) was developed. It was found that the approach is applicable regardless of the hydrodynamic regime (at u_G ≤ 0.1 m/s). Temperatures up to 353 K and pressures up to 0.5 MPa were tested. Two different distributors (multiple‐hole and single‐hole type) were employed. The liquid‐phase mass transfer coefficient k_L was calculated theoretically from the penetration theory on the basis of original definition of gas–liquid contact time. The interfacial area a was defined with respect to the liquid volume. It was found that their product k_La must be multiplied by some correction factor in order to take account of the non‐spherical (ellipsoidal) shape of the bubbles. When the correction term is correlated to both the Eötvös number (Eo) and the dimensionless temperature ratio, 198 experimental k_La values can be fitted reasonably well (average relative error 9.3%).     

Effect of catalyst loading on gasliquid mass transfer in a slurry reactor: A statistical experimental approach

A statistical experimental design was employed to study the effects of pressure, temperature, catalyst loading, and mixing speed on the solubilities (C*) and volumetric gas/liquid mass transfer coefficients (k_L^a) for H₂, N₂, CO, CH₄ and C₂H₄ in a liquid mixture of hexanes containing iron oxide catalyst in a 4-litre agitated autoclave. Statistical correlations for k_L^a values for the gases used were developed. Mixing speed and solid concentration showed the strongest effects on k_L^a. At low catalyst concentrations, a maximum in k_L^a was observed and at concentrations > 37 mass%, k_L^a decreased by more than one order of magnitude.     

Gas-liquid mass transfer in “dead-end” autoclave reactors

Gas-liquid volumetric mass transfer coefficients, (k_La), have been obtained for “dead-end” autoclave reactors operated in two different modes: (a) gas introduced into the gas phase, and (b) gas introduced through a dip-tube in the liquid. Three different methods of k_La determination have been compared. Effects of agitation speed, impeller diameter, gas to liquid volume ratio (V_g/V_L), position of the impeller and reactor size on k_La have been investigated. The k_La data were found to be correlated as: k_La = 1.48 × 10^?3 (N)^2.18 (V_g/V_L)^1.88 (d_I/d_T)^2.16 (h₁/h₂)^1.16 The critical speed of surface breakage, at which transition from the surface convection to the surface entrainment regime occurs, was also determined for different impeller positions, impeller diameters and gas to liquid volume ratios.     

Gas‐liquid mass transfer in low‐ and medium‐consistency pulp suspensions

The volumetric gas—liquid mass transfer coefficient (k_La) was measured for low‐ and medium‐consistency pulp suspensions using the cobalt‐catalyzed sulfite oxidation technique. Mass transfer rates were measured in a high‐shear mixer for a range of operating parameters, including the rotor speed (N = 10 to 50 rev/s), gas void fraction (X_g = 0.10 to 0.40) and fibre mass concentration (C_m = 0.0 to 0.10). k_La measurements were compared with the macroscale flow regime in the vessel (characterized using photographic techniques) and correlated with energy dissipation, gas void fraction and suspension mass concentration in the mixer. We found that gas‐liquid mass transfer was significantly reduced in pulp suspensions, even for low suspension concentrations. Part of this reduction was associated with dissolved components leached from the fibres into the liquid phase. This could account for reductions in k_La of up to 30% when compared with distilled water. The fibres further reduced k_La, with the magnitude of the decrease depending on the fibre mass concentration. Correlations were developed for k_La and compared with results available in the literature.     

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

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

Hydrodynamics,Mass Transfer and Gas Scrubbing in a Co‐current Droplet Column Operating at High Gas Velocities

The main objective of this work was to propose a new process for household fume incineration treatment: the droplet column. A feature of this upward gas‐liquid reactor which makes it original, is to use high superficial gas velocities (13 m s^–1) which allow acid gas scrubbing at low energy costs. Tests were conducted to characterize the hydrodynamics, mass transfer performances, and acid gas scrubbing under various conditions of superficial gas velocity (from 10.0 to 12.0 m s^–1) and superficial liquid velocity (from 9.4·10^–3 to 18.9·10^–3 m s^–1). The following parameters characterized the hydrodynamics: pressure drops, liquid hold‐ups, and liquid residence time distribution were identified and investigated with respect to flow conditions. To characterize mass transfer in the droplet column, three parameters were determined: the gas‐liquid interfacial area (a), the liquid‐phase volumetric mass transfer coefficient (k_La) and the gas‐phase volumetric mass transfer coefficient (k_Ga). Gas absorption with chemical reaction methods were applied to evaluate a and k_Ga, while a physical absorption method was used to estimate k_La. The influence of the gas and liquid velocities on a, k_La, and k_Ga were investigated. Furthermore, tests were conducted to examine the utility of the droplet column for the acid gas scrubbing, of gases like hydrogen chloride (HCl) and sulfur dioxide (SO₂). This is a process of high efficiency and the amount of pollutants in the cleaned air is always much lower than the regulatory European standards imposed on household waste incinerators.     

Efficiency of a Gas‐Liquid Contactor for the Oxygenation of Activated Sludge: Assessment of Mass Transfer Coefficient

The aim of this work is to investigate a co‐current air‐liquid downward flow bubble column with air entrainment by liquid injection nozzle in order to use it as an aerator in activated sludge treatment plants. The study concerns the determination of mass transfer efficiency by measuring the mass transfer coefficient, k_La, both in clean water and in activated sludge. In clean water, this parameter is determined by three methods, i.e., gassing out method, absorption with chemical reaction and off‐gas method. In activated sludge medium, k_La values are measured by two methods, i.e., sludge reoxygenation and the hydrogen‐peroxide method. The values of k_La obtained in clean water are compared to those obtained in sludge, enabling the assessment of the α factor, i.e., ratio of oxygen transfer coefficient sludge/clean water. The results are in good agreement with those reported previously in the literature.     

Power demand and mass transfer capability of mechanically agitated gas-liquid contactors and their relationship to air-lift fermenters

Analysis of established correlations for power uptake, gassed power uptake and overall volumetric mass transfer coefficient (k_La) shows that when operating at constant impeller speed small increases in gas superficial velocity will result in both an increase in k_La) and a decrease in the total power input to the vessel. This is confirmed experimentally. At or near flooding, increasing the superficial velocity will continue to increase k_La still further, but with no further decrease in the agitator power uptake, total power input will increase.The transition region tends to lie on the corresponding k_La vs power input relation for an air-sparged situation (i.e. no mechanical agitation).A given mass transfer capability (k_La) value will be achieved at the same power/unit volume with both air sparged vessels and mechanically agitated vessels providing the gas superficial velocity is greater than 25 mm/sec.     

Bubble size and mass transfer coefficients in dual-impeller agitated reactors

The study relates to the mass transfer and the bubble size in a non standard vessel equipped with various dual-impeller combinations. The effects of the rotational speed, gas flow rate, impeller type and diameter are investigated. The volumetric mass transfer coefficient k_La and the bubble size d_bs were studied. The liquid side mass transfer coefficient k_L and the volumetric interfacial area a were estimated separately. A comparison has been made with some existing correlations.