Prediction of two‐phase pressure drop and liquid holdup in co‐current gas–liquid downflow of air–Newtonian systems through packed beds

The dependency of pressure drop and liquid holdup on phase velocities, geometry of the column and packing materials as well as on the physical properties have been analyzed. Our experimental data (825 data points obtained using four liquid systems and three different particles) along with those of the available literature (776 data point from five different sources) were used for the analysis. The applicability and the limitations of the literature correlations were evaluated using the available data. Based on the analysis, new correlations for the estimation of pressure drop and liquid holdup, valid for low and high interaction regimes have been developed using the available data, with a wide range of variables. Copyright © 2005 Society of Chemical Industry     

Flow pattern transition in gas‐liquid downflow through narrow vertical tubes

The present report studies on the flow pattern transitions during vertical air water downflow through millichannels (0.83 ≤ Eötvös no. ≤ 20.63). Four basic flow patterns namely falling film flow, slug flow, bubbly flow, and annular flow are observed in the range of experimental conditions studied and their range of existence has been noted to vary with tube diameter and phase velocities. Based on experimental observations, phenomenological models are proposed to predict the transition boundaries between adjacent patterns. These have been validated with experimental flow pattern maps from the present experiments. Thus the study formalizes procedure for developing a generalized flow pattern map for gas‐liquid downflow in narrow tubes. © 2016 American Institute of Chemical Engineers AIChE J, 63: 792–800, 2017     

Three‐dimensional simulations of gas‐liquid cocurrent downflow in vertical,inclined, and oscillating packed beds

The hydrodynamic behavior of gas‐liquid downflow in vertical, inclined, and oscillating packed beds related to offshore floating applications was analyzed by means of three‐dimensional unsteady‐state two‐fluid simulations. Angular oscillations of the column between two angled symmetrical positions and between vertical and inclined position were considered while bed non‐uniformity was described using radial porosity distributions. For vertical and slightly inclined columns, two‐phase flow was concentrated in the core area of the bed. However, the two‐phase flow was predicted to deviate significantly from axial symmetry at higher inclinations with prominent liquid accumulation in the bottommost reactor cross‐sectional area. Oscillating packed beds unveiled complex reverse secondary flows radially and circumferentially resulting in oscillatory patterns of liquid holdup and pressure drop whose amplitude and propagation frequency were affected by column inclination angle and travel time between vertical and angled positions. © 2015 American Institute of Chemical Engineers AIChE J, 62: 916–927, 2016     

Influence of liquid viscosity and bed porosity on two‐phase pressure drop in concurrent gas‐liquid upflow through packed beds

It was observed in the experimental investigations that the concurrent upflow of air‐Monoethanol amine system through the packed bed gave higher pressure drop in bubble flow regime than the air‐water system. But when the flow regime changed to spray flow, air‐water system showed higher pressure drop than the other. This phenomenon was observed for the two column packing used in this study. An attempt is made to explain this phenomenon.     

Residence time distribution of the liquid in two-phase cocurrent downflow in packed beds: Air/newtonian and non-newtonian liquid systems

New data on the liquid residence time distribution for two-phase downflow of air-Newtonian and non-Newtonian liquids through packed beds of porous and non-porous particles are presented. The piston-dispersion-exchange model is used to describe the liquid flow. With porous particles the dynamic evolution of the tracer concentration in the particles is described in terms of diffusion phenomena. The axial dispersion is very important in the case of two-phase downflow of air-water (trickle flow regime) and air-CMC systems through fixed beds with porous particles, and is negligible in the case of non-porous particles. With the porous particles, a key value is the effective diffusion coefficient of the tracer in the pores of the particles.     

Hydrodynamics of gas–liquid flow in micropacked beds: Pressure drop,liquid holdup,and two‐phase model

Hydrodynamics of gas–liquid two‐phase flow in micropacked beds are studied with a new experimental setup. The pressure drop, residence time distribution, and liquid holdup are measured with gas and liquid flow rates varying from 4 to 14 sccm and 0.1 to 1 mL/min, respectively. Key parameters are identified to control the experimentally observed hydrodynamics, including transient start‐up procedure, gas and liquid superficial velocities, particle and packed bed diameters, and physical properties of the liquids. Contrary to conventional large packed beds, our results demonstrate that in these microsystems, capillary forces have a large effect on pressure drop and liquid holdup, while gravity can be neglected. A mathematical model describes the hydrodynamics in the micropacked beds by considering the contribution of capillary forces, and its predictions are in good agreement with experimental data. © 2017 American Institute of Chemical Engineers AIChE J, 63: 4694–4704, 2017     

Correlating gas–liquid co‐current flow hydrodynamics in packed beds using the F‐function concept

A phenomenological model based on the generalization of the single‐phase Forchheimer equation was recently proposed for predicting pressure drop and phase saturations in gas–liquid co‐current horizontal and downward high‐pressure packed beds. Here, we extend the model to packed‐bubble (co‐current upflow) and trickle‐bed operation using phase saturation power laws similar to Corey relative permeabilities. The power‐law exponents were fitted using a wide pressure gradient and liquid saturation databank in co‐current up/downward packed‐bed flows. It was found that this approach, as well as other in the literature developed for down‐flow reactors apply also to upward flows; the prediction accuracy was comparable for both flow directions to existing literature approaches. Copyright © 2004 Society of Chemical Industry     

Sensor‐based flow pattern detection—gas–liquid–liquid upflow through a vertical pipe

Flow distribution during gas–liquid–liquid upflow through a vertical pipe is investigated. The optical probe technique has been adopted for an objective identification of flow patterns. The probability density function (PDF) analysis of the probe signals has been used to identify the range of existence of the different patterns. Dispersed and slug flow have been identified from the nature of the PDF, which is bimodal for slug flow and unimodal for dispersed flow. The water continuous, oil continuous, and emulsion type flow distributions are distinguished on the basis of the PDF moments. The method is particularly useful at high flow rates where visualization techniques fail. Based on this, a flow pattern detection algorithm has been presented. Two different representations of flow pattern maps have been suggested for gas–liquid–liquid three phase flow. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3362–3375, 2014     

Effect of pulsing on reaction outcome in a gas–liquid catalytic packed-bed reactor

A novel experiment is described for studying the effect of flow regime on reaction outcome for a consecutive-parallel reaction. By taking advantage of the convective nature of disturbances that grow into pulses in gas–liquid packed-bed reactors, it is shown that it is possible to compare reaction behavior for pulsing and trickling at the same flow rates. This contrasts previous studies where effects of regime were found, but at different flow rates. This experiment is accomplished by packing the column with mostly inert particles and confining the catalytically active region either near the inlet, where pulses have not yet formed, or near the end where they have developed. It is found that for the reaction of phenylacetylene to styrene and ethylbenzene over a platinum/alumina catalyst, where pulses are present in the bottom of the reactor but not at the top, about a 15% increase in styrene concentration, as an intermediate, occurs under pulsing conditions.     

Emulation of gas‐liquid flow in packed beds for offshore floating applications using a swell simulation hexapod

A laboratory‐scale packed column was positioned on a six degree of freedom swell simulation hexapod to emulate the hydrodynamics of packed bed scrubbers/reactors onboard offshore floating systems. The bed was instrumented with wire mesh capacitance sensors to measure liquid saturation and velocity fields, flow regime transition, liquid maldistribution, and tracer radial and axial dispersion patterns while robot was subject to sinusoidal translation (sway, heave) and rotation (roll, roll + pitch, yaw) motions at different frequencies. Three metrics were defined to analyze the deviations induced by the various column motions, namely, coefficient of variation and degree of uniformity for liquid saturation fluctuating fields, and effective Péclet number. Nontilting oscillations led to frequency‐independent maldistribution while tilting motions induced swirl/zigzag secondary circulation and prompted nonuniform maldistribution oscillations that deteriorated with decreasing frequencies. Regardless of excited degree of freedom, a qualitative loss of plug‐flow character was observed compared with static vertical beds which worsened as frequencies decreased. © 2015 American Institute of Chemical Engineers AIChE J, 61: 2354–2367, 2015     

A hydrodynamic model of a circulating fluidised bed with low‐density particles

In this study, a two‐dimensional mathematical model was developed considering the hydrodynamic behaviour of a circulating fluidised bed biomass gasifier (CFBBG), which is also applicable for other low‐density particles. In the modelling, the CFB riser was divided into two regions: a dense region at the bottom and a dilute region at the top of the riser. Kunii and Levenspiel's [Kunii and Levenspiel, Powder Technol. 61, 193‐206 (1990)] model was adopted to express the vertical solids distribution with some other assumptions. Radial distributions of bed voidage were taken into account in the upper zone by using Zhang et al.'s [Zhang et al., Chem. Eng. Sci. 46(12), 3045‐3052 (1991)] correlation. For model validation purposes, a cold model CFB was employed, in which sawdust was transported with air as the fluidising agent. The column is 10 m in height and 280 mm in diameter, and is equipped with pressure transducers to measure axial pressure profile and with a reflective optical fibre probe to measure local solids holdup. A satisfactory agreement between the model predictions and experimental data was found. © 2011 Canadian Society for Chemical Engineering     

Phase separation of gas–liquid two‐phase stratified and plug flows in multitube T‐junction separators

Using air and water as the working fluids, phase separation phenomena for stratified and plug flows at inlet were investigated experimentally, at a simple T‐junction and specifically designed multitube T‐junction separators with two or three layers. The results show that for these two flow patterns the separation efficiency of the two phases for any multitube T‐junction separator is much higher than that of the simple T‐junction. Increasing the number of connecting tubes in the multitube T‐junction separator can increase the separation efficiency. Generally, for stratified flow, complete separation of the two phases can be achieved by the two‐layer multitube T‐junction separator with five or more connecting tubes and by the three‐layer separator; increasing the gas flow rate, the liquid flow rate, or the mixture velocity under plug flow is detrimental to phase separation with a drop in peak separation efficiency. © 2016 American Institute of Chemical Engineers AIChE J, 63: 2285–2292, 2017     

Inception and termination of the core‐annular flow pattern for oil‐water downflow through a vertical pipe

Different flow patterns for lube oil–water and for kerosene‐water downflow through a vertical glass tube have been analyzed with the help of flow visualization. Core‐annular flow is the dominant flow regime, with oil forming the core, and water is forming the wall film. When the velocities are increased, transition to slug flow and transition to dispersed flow are found. The waves found during the transition to slug flow depend on oil viscosity: axisymmetric bamboo waves are seen in kerosene‐water downflow and the waves are asymmetric in case of lube oil–water flow where they have a cork‐screw shape. Based on the experimental observations, simple mathematical models have been proposed for predicting the flow pattern transition curves. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

Process intensification in particle technology: Characteristics of powder coatings produced by nonisothermal flow‐induced phase inversion

The characteristics of powder coatings manufactured through a novel processing technique based on nonisothermal Nlow‐induced phase inversion granulation enhanced by fluid injection to promote phase inversion and particle formation from melt state is summarized. Experiments were carried out in a purpose‐built granulator, which operates in a parallel disk rotor‐stator arrangement, so that the mechanism of granulation could be studied. The product of this intensive granulation was compared with that of the conventional powder coating manufacturing process. Understanding the mechanism of intensive granulation helped to redesign the equipment that resulted in smaller particles. Pigment dispersion characteristics were improved by intensive granulation. Also, the particle size span can be significantly reduced by dry granulation and gas‐phase granulation, and the flowability can be improved by wet granulation. Chemical analysis of particles by Fourier transform infrared spectroscopic analysis showed that the injection of coolant fluid had no effect on the chemical composition. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

Treatment of settled piggery waste by a down‐flow anaerobic fixed bed reactor

A study of the effect of organic volumetric loading rate (B_V) on the performance of a down‐flow anaerobic fixed bed reactor (DFAFBR) treating settled piggery waste was carried out at a range of between 1.1 and 6.8 g COD dm^?3 d^?1. The reactor operated at good removal efficiencies and stability under the operational conditions studied. Logarithmic empirical equations described adequately the removal efficiency for different parameters studied (COD, SCOD, BOD, TS, VS, TSS, VSS and phosphorous). Although process stability was affected by the increase of B_V, process failure was not observed. A logarithmic relationship was found to describe the influence of B_V on the TVFA/alkalinity ratio (p). A linear correlation was found between the effluent substrate concentration and the values of p and between p and the CO₂/CH₄ ratio in the biogas. The effect of the hydraulic volumetric loading rate (H_V) on the flow pattern of the reactor was evaluated. Dispersion number (D_n) was in the range of 0.17–0.37 for the maximum and minimum values of H_V studied, respectively. The ratio between the real and theoretical HRT increased as the H_V decreased. These results demonstrate that axial dispersion increased as the H_V and the Reynolds number decreased. Due to the hydraulic behaviour of the reactor, the kinetic model developed by Lawrence and McCarty was used for describing the experimental results obtained. Maximum specific substrate removal rate (K), specific organic loading rate constant (K_L), microbial decay coefficient (K_d), microbial yield coefficient (Y), maximum microbial growth rate (U_M) and saturation constant (K_S) were found to be: 3.1 (g COD g VSS^?1 d^?1), 3.0 (g COD g VSS^?1 d^?1), 0.062 (d^?1), 0.15 (g VSS g COD removed^?1), 0.39 (d^?1) and 2.6 (g SCOD dm^?3), respectively. Copyright © 2004 Society of Chemical Industry     

Realization and control of multiple temperature zones in liquid‐containing gas–solid fluidized bed reactor

Fluidized bed reactors (FBRs) have been developed to establish multiple temperature zones for various industrial processes. To overcome the common weakness, this work proposed to spray liquid into bottom and upper zones, respectively, to realize multiple temperature zones FBR (MTZFBR). Temperature, pressure, and acoustic emission techniques were applied to fully characterize liquid interaction and hydrodynamics. Compared with the bottom liquid‐spraying approach, the upper liquid‐spraying approach showed higher temperature difference (ΔT) and better fluidization stability, thus was selected for further control studies. Effects of liquid flow rate, static bed height, and inlet gas temperature on MTZFBR were studied systematically. The results showed that increasing liquid evaporation behavior or decreasing liquid bridge behavior enhance ΔT and fluidization stability and vice versa. G–L–S fluidization pattern depended mostly on the liquid behaviors and fluidization stability, and thus the stabilized MTZFBR could be regarded as a coexisted mode of two distinctive G–L–S fluidization patterns. © 2016 American Institute of Chemical Engineers AIChE J, 62: 1454–1466, 2016     

Liquid‐bridge flow in the channel of helical string and its application to gas–liquid contacting process

To solve the problems of the traditional packings, such as high pressure drop, mal‐distribution and short liquid residence time, a helical flow structured packings was proposed. Two different flow patterns, liquid‐bridge flow and liquid‐drop flow were identified when the width of the channel of the helical string was adjusted. Moreover, the characteristics of the helical liquid‐bridge flow including maximum liquid loading, mean thickness of liquid film, mean residence time and effective specific surface area, were examined. And the separation efficiency was studied by the lab‐scale distillation column. In comparison, the effective specific surface area of the helical flow type packings is almost as large as the traditional B1‐350Y structured packings, but with thinner liquid film, longer liquid residence time and finally higher separation efficiency. © 2018 American Institute of Chemical Engineers AIChE J, 64: 3360–3368, 2018     

Hydrodynamics and reactor performance evaluation of a high flux gas‐solids circulating fluidized bed downer: Experimental study

Reactor performance of a high flux circulating fluidized bed (CFB) downer is studied under superficial gas velocities of 3–7 m/s with solids circulation rate up to 300 kg/m²s using ozone decomposition reaction. Results show that the reactant conversion in the downer is closely related to the hydrodynamics, with solids holdup being the most influential parameter on ozone decomposition. High degree of conversion is achieved at the downer entrance region due to strong gas‐solids interaction as well as higher solids holdup and reactant concentration. Ozone conversion increases with the increase of solids circulation rate and/or the decrease of superficial gas velocity. Overall conversion in the CFB downer is less than but very close to that in an ideal plug flow reactor indicating a good reactor performance in the downer because of the nearly “ideal” hydrodynamics in downer reactors. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3412–3423, 2014