Modeling gas absorption accompanied by chemical reaction in bubble column and foam-bed slurry reactors

The published data in the literature and the reported models on foam-bed reactors have been reanalyzed. It is observed that the models have been developed assuming negligible conversion in the storage section although the storage constitutes 65–85% of the total volume of liquid/slurry charged into the reactor. For confirmation of the reported information, in the present work, experiments have been performed in foam-bed and bubble column slurry reactors for carbonation of hydrated lime slurry using carbon-dioxide gas under identical conditions. A comparison of the relative performances of the two reactors has been made. Storage section is found to be the main section governing the performance of the foam-bed slurry reactor. New mathematical models have been developed for both the reactors. The model predictions agree well with the experimental data.     

Gas Absorption with Chemical Reaction and Desorption in a Foam-bed Reactor

A general model of a foam-bed reactor involving simultaneous gas absorption, reaction, and desorption has been developed. The model considers all coupled processes in the reactor. The reactive gas absorption and desorption in the foam section have been simulated via analysis of a single foam film surrounded by limited gas pockets. The model includes a sub-model to find out concentration profiles inside the surface element. A modular approach has been used to simulate a single foam film to obtain transient concentration profiles of the gas-phase reactant A and product P. Effects of various kinetic, physicochemical, operating, and system parameters like reaction velocity, diffusion coefficient, solubility, contact time, and holdup on fractional absorption and desorption of gas are studied.     

Gas absorption with zero-order chemical reaction in a foam-bed reactor

A mathematical model for oxidation of aqueous alkaline solution of sodium dithionite using air as an oxidizing medium in a foam-bed reactor has been developed under pseudo-zero-order conditions of reaction and was found to be in good agreement with the experiments. Reactor conditions were 30°C at atmospheric pressure and surfactant used in the foam contactor was octyl phenoxy polyethoxyethanol (Triton X-100). The results of simulation for concentration profiles of the dissolved gas-phase reactant inside foam film based on above model are presented for different gas flow rates, reaction rates, and times of contact. The effects of variables such as superficial gas velocity and initial liquid-phase reactant concentration on conversion are also studied and compared with experiments on oxidation of sodium dithionite. The results indicate that the conversion increases with the increase in the superficial air velocity and initial dithionite concentration. The model predicts the experimentally obtained conversions reasonably well.     

Analysis of gas absorption accompanied by a zero-order chemical reaction in a liquid-foam film surrounded by limited gas pockets

Gas absorption accompanied by a zero-order chemical reaction in a finite liquid-foam film has been analysed to obtain expressions for the amount of gas absorbed and for fractional absorption in such a film. These equations may be readily incorporated into a single-stage model of a foam-bed reactor to extend it to chemisorption with zero-order kinetics. The equations for physical absorption result naturally from a special case.     

Computation of plate columns for NOx absorption by a new stage-to-stage method

A new stage-to-stage method has been developed for the calculation of NX_x absorption columns. Each stage of the absorption column is simulated as a combination of a bubble column reactor (absorption) and an adiabatic plug for reactor (oxidation). The bubble column reactor is modelled as two single stirred tank reactors, one as a gas-phase and one as a liquid-phase reactor, both coupled by mass and heat transfer. In this hydrodynamic model, a dynamic approach is adopted, in which the gas-phase transport of N₂O₄ is the limiting step for the absorption. A gas-phasepseudo-enhancement for factor for N₂O₄ is therefore introduced. The balance equations for a single phase of the bubble column are solved with a Newton-Raphson algorithm. The entire column calculation is divided into a gas and a liquid side. On both sides, the stage-to-stage method is applied in such way that the overall calculation is performed as a loop process. The direction of the loop calculation follows that of the flow: gas-side upwards and liquid-side downwards.     

MASS TRANSFER WITH CHEMICAL REACTION IN A FROTH BED REACTOR

A model to predict conversions in a froth bed reactor has been developed. The model is then compared against the available experimental data on the oxidation of sodium sulfide in a foam bed contactor. The predictions using the present model are also compared against those based on the model of a foam bed reactor developed earlier. The predictions using the present model agree fairly well with the experimental data and, in some cases, are even in better quantitative agreement than the previous single stage model of a foam bed reactor. The case of significant surface resistance due to surfactant has also been analyzed theoretically, obtaining analytical solutions for the concentration profile and fractional gas absorption in a liquid froth shell.     

A fluid-dynamically based model of bubble column reactors

A heterogeneous fluid dynamic model has been developed to describe the complex flow structure of two-phase in bubble columns. The equation of continuity and momentum balances form the basis of the model. Coupling of the two phases occurs via an interaction force, deduced by a force balance around a single rising bubble. Multiphase flow mixing processes are taken into consideration by introducing turbulent viscosities of the two phases involved. The Simulation program was extended to reactive system, taking into account the mass balances of a second order gas-liquid chemical reaction as well as the different absorption/reaction regimes. The gas phase concentration profiles show pronounced axial and radial dependences, while the liquid phase can be regarded as a CSTR with respect to the liquid component. With reference to the gaseous component, which is being absorbed in the liquid phase, the degree of back mixing does not show CSTR behaviour as the influence of different absorption conditions in different axial and radial reactor positions is superposed on that of turbulent motion of the liquid carrier of the dissolved gaseous component.     

Numerical Simulation of Dispersed Gas/Liquid Flows in Bubble Columns at High Phase Fractions using OpenFOAM®. Part II – Numerical Simulations and Results

The design of industrial gas/liquid reactors such as bubble columns requires detailed information with respect to the flow structure and characteristics of two‐ or multiphase systems in the reactor. The contribution is focused on the evaluation of the simulation results obtained by model selection. The results are further compared with those reported in literature. The simulation has been performed with the CFD software OpenFOAM®. The main focus of the numerical simulation was set on capturing the characteristic process and design parameters of bubble columns.     

Development of bubble column for foam separation

The foam separation of metal in model wastewater is performed by using two different bubble columns in a continuous operation mode. The equipment and operation conditions are changed, and the foam flow rate and metal concentration in foam flow are measured. The foam flow ratio (the ratio of foam flow rate to the inlet one) increases with increasing gas velocity, with decreasing liquid velocity, with decreasing foam layer height and with decreasing metal concentration in model wastewater. Metal enrichment (the ratio of metal concentration in foam flow to that in inlet flow) shows the reverse tendencies. When a draft tube is inserted in the bubbling layer, the foam flow rate decreases. The enrichment is strongly governed by the foam flow ratio. Since the foam flow ratio is adjusted by means of the equipment and operation conditions, the metal concentration in foam flow is controlled to be a desired value. This paper was presented at The 5th International Symposium on Separation Technology-Korea and Japan held at Seoul between August 19 and 21, 1999.     

Optimization of Gas Scrubbing in the Calcination of Struvite

During the calcination of magnesium ammonium phosphate hexahydrate (struvite) in the process of recycling to obtain phosphoric acid, ammonia is released in addition to water and carbon dioxide. With a gas scrubber, e.g., in the form of a bubble column reactor, ammonia can be recovered as a usable valuable material. With water as an inexpensive and effective absorbent, almost complete absorption (92 %) of the ammonia from the exhaust air can be achieved.     

Absorption in packed bubble columns

The mass transfer characteristics of packed bubble columns were studied by employing various packings of different sizes and shapes in 10–38·5 cm i.d. columns. The theory of absorption accompanied by pseudo-mth order reaction was used to obtain the values of effective interfacial area. The values of liquid side mass transfer coefficient were obtained by using the theory of absorption accompanied by slow chemical reaction. The superficial gas velocity was varied from 5 to 25 cm/sec. The packed bubble columns showed a considerable improvement in the performance over empty bubble columns. A criterion for the scale-up of these columns has been suggested.     

Hydrodynamics of churn turbulent bubble columns: gas–liquid recirculation and mechanistic modeling

A phenomenological (mechanistic) model has been developed for describing the gas and liquid/slurry phase mixing in churn turbulent bubble columns. The gas and liquid phase recirculation rates in the reactor, which are needed as inputs to the mechanistic reactor model are estimated via a sub-model which uses the two-fluid approach in solving the Navier–Stokes equations. This sub-model estimates the effective bubble diameter in the reactor cross-section and provides a consistent basis for the estimation of the volumetric mass transfer coefficients. The strategy for the numerical solution of the sub-model equations is presented along with the simulation results for a few cases. The overall reactor model has been tested against experimental data from radioactive gas tracer experiments conducted at the Alternate Fuels Development Unit (AFDU), La Porte, TX under conditions of methanol synthesis.     

Experimental model validation of an integrated process for the removal of carbon dioxide from aqueous ammonia solutions

In this work modelling and experimental validation of an integrated process for the removal of carbon dioxide from ammonia solutions - the so called decarbonisation - is presented. In this process, carbon dioxide and small amount of ammonia is stripped out from the solution at ambient pressure in a packed column. Recovery of the stripped ammonia can be reached by combining absorption of ammonia and condensation of stripping steam. The integration of stripping, absorption and direct-contact condensation (DCC) can be achieved in one compact unit in which stripping takes place in the lower part of the packed column, and the DCC and ammonia absorption in its upper part. This unit has been modelled in a rigorous way considering heat and mass transfer as well as reaction rates in multicomponent reactive stripping, absorption and direct-contact condensation in packed columns (Ma?kowiak et al., 2009). Extensive experimental investigations in a pilot scale packed column with diameters of 0.15 and 0.32 m have been performed for both, the stripping and for DCC. Relevant operation parameters as well as column dimensions were varied during the experiments in order to investigate their influence on the selectivity of the decarbonisation and to achieve a broad data base for the validation. Experimental validation of the two sub-processes and the entire decarbonisation shows good agreement between calculated and experimental values. Based on the validated model a successful optimisation of the decarbonisation process in industrial scale has been performed, leading to increased carbon dioxide removal and reduction of ammonia losses.     

钴膦催化剂丙烯低压醛化制丁醇数学模型的研究

本文报导丙烯低压醛化制丁醇气液并流填料鼓泡反应器的数学模型的研究.在实验室模型级装置上验证了该数学模型的结果,表明带有接触效率系数的本征动力学方程式可以作为丙烯低压醛化制丁醇的反应器数学模型,为放大设计提供参考.     

Absorption of ammonia in a batch bubble column

The batch neutralization of dilute hydrochloric acid by ammonia in a 10.16 cm i.d. bubble column has been examined. Experimental results agree with a diffusion-type mixing model when 5.08 cm disc baffles are present, but agreement is only approximate with 7.62 cm diameter baffles. Axial dispersion coefficients have been determined and compared with published data. A simple batchwise procedure for evaluating bubble columns is suggested.     

Absorption of ammonia in a batch bubble column

The batch neutralization of dilute hydrochloric acid by ammonia in a 10.16 cm i.d. bubble column has been examined. Experimental results agree with a diffusion-type mixing model when 5.08 cm disc baffles are present, but agreement is only approximate with 7.62 cm diameter baffles. Axial dispersion coefficients have been determined and compared with published data. A simple batchwise procedure for evaluating bubble columns is suggested.     

Operating characteristics of special bubble column reactors

In chemical technology, bubble column reactors are often used to carry out gas-liquid conversions. Thus hydrogenation, hydroformylation, oxidation, sulphoxidation and chlorination are carried out in bubble columns, as are also fermentations and sewage water treatment processes. A considerable advantage of bubble column reactors as against other gas-liquid contact apparatus is their simplicity of construction without mechanically moving parts or parts subject to high wear and tear.The purpose of this paper is to report on the possible applications and on the behaviour in operation of specially designed and constructed bubble column reactors, for example, cascade bubble columns, bubble columns with internal or external loops and downflow bubble columns.The designs of bubble column reactor described here are used in the chemical industry for various process (Table 2).In the development of new process, there are often several different competing designs. The ultimate choice will depend on the operating characteristics discussed here.     

Bubble size distribution and energy dissipation in foam mixers

The bubble size distribution of a foam produced in a rotor-stator mixer has been determined as a function of several mixing parameters such as the rotor speed, residence time, gas/liquid ratio and the viscosity of the liquid used. A Newton-Reynolds expression for a foam mixer has been determined using energy consumption measurements. Two types of shear fields have been distinguished in the foam mixer, laminar and turbulent, the type of shear field depending on the properties of the foam mixer. After a certain mixing time the bubble size distribution characterised by the mean bubble size was found to reach a stationary value. The stationary bubble size distribution has been correlated with the mixing conditions by a critical Weber number. Both in the laminar and in the turbulent shear field bubble size distributions have been determined as a function of several mixing parameters.