CFD and experimental studies of reactive pulsing flow in environmentally-based trickle-bed reactors

Pulsing flow in trickle-bed reactors (TBRs) has been claimed to promote the averaged heat and mass transfer rates, thereby enhancing the overall conversion and productivity. In this work, we focused on the mineralization of organic matter by catalytic wet oxidation at different liquid flow modulations. The convective nature of the disturbances that lead to pulsing was simulated by an Eulerian Computational Fluid Dynamics (CFD) model and validated with experimental data. In order to evaluate the predicted effects of pulsing on reaction outcome, first the multiphase flow governing equations were detailed with the computational methodology used in the simulation procedure. Prominent numerical parameters were optimized in terms of mesh aperture and time step. Second, to enable objective assessments of the merits of the different cyclic strategies, several computational runs were performed addressing the effect of nominal gas and liquid flow rates as well as the oxidation temperature. Here, we found that the concentration profile computed by the CFD model for pulsing flow conditions demonstrated superior oxidation performance over the trickling flow regime, which has been further corroborated by experimental evidences. Afterwards, the normalized concentration series close to the top of the TBR exhibited sharp fronts and gradually become less intense as they travel downward that reflected the nonisolated nature of the traveling liquid pulsations. Finally, these computational and experimental findings enabled us to intensify the detoxification of high-strength wastewaters and can be further exploited due to advantageous dispersive and convective heat/mass transfer phenomena under pulsing flow conditions.     

An investigation of liquid maldistribution in trickle beds

The influence of liquid maldistribution at the top of the packing on flow characteristics in packed beds of gas and liquid cocurrent downflow (trickle beds) is experimentally investigated. Particular attention is paid to the effect of gas and liquid flow rates on flow development. Tests are made in the trickling and pulsing flow regimes. A uniform, a half-blocked and a quarter-blocked liquid distributor is tested. Packings of various sizes and shapes are employed. Data are presented on pressure drop and liquid holdup as well as trickling to pulsing flow transition. Diagnosis of radial and axial liquid distribution is made by means of conductance probes. The effects of liquid foaming, bed pre-wetting, top-bed material, and blockage midway the bed on liquid distribution are also examined. Overall, liquid waves in the pulsing flow regime have a beneficial effect, promoting uniform liquid distribution in the bed cross section.     

Multiphase reacting flow studies of bubble column ozonation reactor for water remediation

A multiphase Volume‐of‐fluid (VOF) model was developed to gain further insights into the reactive flow parameters and electrical capacitance tomography (ECT) measurements on the remediation of hazardous organic pollutants. Low ozone bubble frequencies were obtained for high surface tension fluids, and the liquid viscosity affected the ozone bubbling frequency. The VOF model indicated that the increase of inlet gas velocity enriched the ozone bubble detachment and concomitantly generated larger ozone bubbles, decreasing the detoxification rates. VOF mappings and ECT visualizations of gas‐liquid unveiled preferential routes and highlighted the attenuation of the axisymmetric behavior of the ozonation bubble column under high‐interaction regimes.     

滴流床中持液量及流型转变的一维流体力学模型

针对滴流床中均匀球形填料,在颗粒尺度上分析气液两相在颗粒空隙中的流动.从基本的流体力学方程出发,建立了微观流动模型,求得滴流区液相在填料表面上的分布,进而计算液相总持液量,并通过对液膜波的稳定性分析,提出了滴流区向脉动区转变的判据.模型与实验结果及文献值作了比较,符合程度较好.     

Measurements and modeling of heat generation in a trickling biofilter for biodegradation of a low concentration volatile organic compound (VOC)

The experimental and theoretical heat generation behavior of a trickling biofilter treating toluene is discussed. The experimental results show that the temperature of the packed bed has a significant effect on the purification performance of the trickling biofilter and that an optimal operation temperature exists between 30 and 40 °C. During the gas–liquid co-current flow, the temperature in the packed bed gradually rises along the direction of the gas and liquid flow due to the exothermic biodegradation of toluene. The temperature rise between the inlet and outlet of the trickling biofilter increases with an increase in the gas flow rate and inlet toluene concentration. In addition, a larger liquid flow rate leads to a smaller temperature rise. The heat generation process occurring in the trickling biofilter is modeled by representing the packed bed as an equivalent set of parallel capillary tubes covered by the biofilm. The temperature profile in the packed bed during the liquid–gas co-current flow is analyzed by simultaneously solving the problem of gas–liquid two-phase flow and heat and mass transfer through the liquid film and biofilm. It is shown that the model agrees well with the experimental data, predicting the variations of the temperature rise between the inlet and outlet of trickling biofilter with the increasing gas and liquid flow rates.     

Volume‐of‐fluid‐based model for multiphase flow in high‐pressure trickle‐bed reactor: Optimization of numerical parameters

Aiming to understand the effect of various parameters such as liquid velocity, surface tension, and wetting phenomena, a Volume‐of‐Fluid (VOF) model was developed to simulate the multiphase flow in high‐pressure trickle‐bed reactor (TBR). As the accuracy of the simulation is largely dependent on mesh density, different mesh sizes were compared for the hydrodynamic validation of the multiphase flow model. Several model solution parameters comprising different time steps, convergence criteria and discretization schemes were examined to establish model parametric independency results. High‐order differencing schemes were found to agree better with the experimental data from the literature given that its formulation includes inherently the minimization of artificial numerical dissipation. The optimum values for the numerical solution parameters were then used to evaluate the hydrodynamic predictions at high‐pressure demonstrating the significant influence of the gas flow rate mainly on liquid holdup rather than on two‐phase pressure drop and exhibiting hysteresis in both hydrodynamic parameters. Afterwards, the VOF model was applied to evaluate successive radial planes of liquid volume fraction at different packed bed cross‐sections. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

Flow Regimes of Viscous Immiscible Liquids in T‐Type Microchannels

A computational and experimental study of the flow regimes of a mixture of castor and paraffin oils in a T‐type microchannel with 200 × 400 µm cross section was carried out. The ranges of parallel, slug, droplet, and rivulet flow regimes of the tested mixture were defined. According to the experimental results, a flow regime map was constructed for this mixture depending on the Weber number multiplied by the Ohnesorge number. A correlation of the length of paraffin oil slugs to the fluid flow ratio was established. The experimental data were compared with results of numerical simulation. A good agreement between calculation and experimental data was achieved in terms of reproduction of flow regimes, phase boundaries, and slug length.     

Onset of pulsing in gas-liquid trickle bed filtration

When liquid suspensions containing low concentration of fine solids are treated in catalytic packed bed gas-liquid-solid reactors, which are operated in trickle flow or near the transition between trickle and pulse flow, plugging develops and increases the resistance to two-phase flow. Also due to obstruction, such accumulation of fines in the catalyst bed shifts progressively the flow pattern from trickling to pulsing flow. The progressive onset of pulsing flow along the packed bed was estimated using a sequential approach based on combining a “large time-scale” unsteady-state filtration solution of two-phase flow with a “short time-scale” solution of a linear stability analysis of two-phase flow. Space-time evolution and two-phase flow of the deposition of fines in trickle bed reactors under trickle flow regime was described using a one-dimensional two-fluid model based on the volume-average mass and momentum balance equations and volume-average species balance equation for the fines. The model hypothesized that plugging occurred via deep-bed filtration and incorporated physical effects of porosity and effective specific surface area changes due to the capture of fines, inertial effects of phases, and coupling effects between the fines filter rate equation and the interfacial momentum exchange force terms. The transition between trickle flow and pulse flow regimes was described from a stability analysis of the solution of the transient two-fluid model around an equilibrium state of trickle flow under pseudo steady state conditions. The impact of liquid superficial velocity, viscosity and surface tension, gas superficial velocity and density, feed fines concentration, and fines diameter on the transition between trickle and pulse flows in the presence of fines deposition was analyzed.     

Computational Fluid Dynamics Modeling of Gas‐Liquid Two‐Phase Flow around a Spherical Particle

Microscale studies, which can provide basic information for meso‐ and macroscale studies, are essential for the realization of flow characteristics of a packed bed. In the present study, the effects of gas velocity, liquid velocity, liquid‐solid contact angle, and liquid viscosity on the flow behavior were parametrically investigated for gas‐liquid two‐phase flow around a spherical particle, using computational fluid dynamics (CFD) methodology in combination with the volume‐of‐fluid (VOF) model. The VOF model was first validated and proved to be in good agreement with the experimental data. The simulation results show that the film thickness decreases with increasing gas velocity. This trend is more obvious with increasing operating pressure. With increasing liquid velocity, the film thickness tends to be uniform on the particle surface. The flow regime can change from film flow to transition flow to bubble flow with increasing contact angle. In addition, only at relatively high values does the liquid viscosity affect the residence time of the liquid on the particle surface.     

Hydraulic characteristics of biological filters

Relationships between the removal efficiency and the hydraulic regimes of trickling filters were investigated. At low flow rates, where break-up of liquid jets occurs and drops form, completely mixed conditions prevail. For large hydraulic loadings effluent concentrations were calculated by means of a dispersed plug flow model. The ranges of validity of these models were studied theoretically. The effects of drop formation and breakage of liquid jets on the substrate utilization are expressed in terms of hydraulic and physical properties of the media and liquid.     

Modeling the disintegration of cavitating turbulent liquid jets using a novel VOF–CIMD approach

In this article, a novel modeling approach capable of simultaneously tracking the events of cavitation, occurring within an injector nozzle, and the liquid jet breakup process, inclusive of spray formation, in the nozzle exterior is presented. A single fluid model, embedded with a Volume-of-Fluid (VOF)-based interface capturing methodology for monitoring the liquid–gas interface dynamics, is supplemented with a vapor transport model for predicting cavitation events triggered within the liquid. While the surface forces due to liquid–gas interfacial instabilities are modeled using a Continuum Surface Force model, a Cavitation-Induced-Momentum-Defect (CIMD) correction approach is employed to account for the effects of cavitation dynamics within the liquid flow. Liquid turbulence is modeled using the well-known RNG k–ε model inclusive of new source terms due to cavitation-induced turbulent kinetic energy production and dissipation. The combined VOF–CIMD methodology is validated by examining the effects of cavitation on the disintegration of turbulent planar liquid jets exiting a two-dimensional nozzle. Different flow Reynolds and Cavitation number configurations are tested. The results predicted by the model including those of the transport vapor dynamics and the liquid jet disintegration processes match, both qualitatively and quantitatively, very well with the available experimental data. In comparison with experimental observation, our model predicts different regimes of liquid jet behavior such as wavy jet, spray formation simultaneously with events of developing or super-cavitation. The numerical approach elaborated in this article can be extensively applied in the design and development of efficient spray applicators and other industrial fluidic devices.     

Prediction of Two‐Phase Frictional Pressure Drop for the Concurrent Gas and Newtonian Liquids Upflow through Packed Beds

Correlations were developed to predict frictional pressure drop for concurrent gas‐liquid upflow through packed beds covering all the three identified flow regimes, i.e. bubble flow, pulse flow and spray flow. The observation that the gas and liquid flow rates have different influences on the two‐phase pressure drop in different flow regimes, was taken into consideration in the development of these correlations. More than 600 experimental pressure drop data from the present study and literature covering a wide range in gas‐liquid systems, flow rates and column packing were used.     

Studies on Liquid—Gas and Three‐Phase Fluidized Beds with Pulsating Air Flows

The effects of air‐flow pulsation and water and air flowrates on the hydrodynamics of liquid—gas and three‐phase fluidized beds containing 3‐mm glass beads have been studied in a 90‐mm i.d. column. Under steady‐flow conditions, both types of bed contained a relatively large number of small bubbles. With a pulsing air flow, however, a smaller number of much larger bubbles or slugs were formed. This was attributed to different mechanisms of bubble formation at the distributor. Variations in phase holdup were explained in terms of the effects of the operating parameters on the bubble characteristics.     

A study of local liquid/solid mass transfer in packed beds under trickling and induced pulsing flow

Induced pulsing flow (by cyclic liquid feeding) in packed beds, operated in the trickling flow regime, is studied as a method of overall improvement of catalytic reactor operation. In this paper results are reported of experiments aimed at determining local and global liquid/solid mass transfer rates, mainly for the so-called fast mode of ON-OFF periodic liquid feeding, with frequencies of order 0.1 Hz. Such mass transfer data for the fast mode of induced pulsing are not available in the literature. Uniform 6 mm glass spheres and alumina cylindrical extrudates, of 1.5 mm diameter and a narrow distribution of lengths, are employed in the tests. For completeness, results are also reported for single-phase (liquid) and trickling flow through the same packed beds. A well-known electrochemical technique is employed to measure instantaneous local mass transfer coefficients by means of quite a few probes distributed throughout the bed. The hydrodynamic characteristics under the above conditions, reported in companion papers, are helpful in interpreting the new mass transfer data.There is a wide spread of the time-averaged local mass transfer rates, in all cases tested, apparently due to packing and flow non-uniformities. This spread is much smaller in the case of packed uniform spheres. In general, the benefits of cyclic liquid feeding are more evident in the packed bed of spheres than in that of cylindrical extrudates; for instance, with increasing mean liquid rate, induced pulsing tends to reduce the spread of local mass transfer coefficients, which suggests that more uniform fluids distribution is promoted. The imposed liquid pulses are reflected in the observed periodic variation of local mass transfer coefficients; the latter appear to decay along the bed in the same manner as the liquid pulses. Other trends of local mass transfer rates are identified and discussed in relation to measured variation of liquid holdup, under the same conditions. For packed spheres, the measured global mass transfer rates are in fair agreement with literature correlations obtained for the trickling flow regime, unlike the case of packed extrudates where significant deviation is observed.     

Kinetic Study of Leuco‐Indigo Carmine Oxidation and Investigation of Taylor and Dean Flow Superposition in a Coiled Flow Inverter

In two‐phase capillary flow, Taylor and Dean vortices can enhance mass transfer according to recent studies. By utilizing a colorimetric method based on the consecutive oxidation of leuco‐indigo carmine it is possible to visualize the superposition of Taylor and Dean vortices in a gas‐liquid system. A kinetic study is performed in order to estimate the enhancement factor. Depending on the flow conditions, three different flow regimes are identified with different intensities of Taylor and Dean vortices affecting the oxygen distribution within the liquid phase. A dimensionless number is derived that describes this transition in flow regimes.     

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.     

CFD modelling of flow and heat transfer in the Taylor flow regime

Transport phenomena in the Taylor flow regime for gas–liquid flows in microchannels have received significant attention in recent years. Whilst the hydrodynamics and mass transfer rate in the Taylor flow regime have been studied extensively using experimental and numerical techniques, studies of heat transfer in Taylor flow have been neglected. In this work, the flow and heat transfer in this regime is studied using the volume of fluid (VOF) and level-set techniques to capture the gas–liquid interface, as implemented in the ANSYS Fluent and TransAT codes, respectively. The results obtained from the two different codes are found to match very closely. Fully-developed flow and heat transfer are studied using the VOF method for a Reynolds number (Re) of 280, Capillary number (Ca) of 0.006 and homogeneous void fraction (β) of 0.51 for constant wall heat flux (H) and constant wall temperature (T) boundary conditions. The Nusselt numbers obtained for both cases are 2.5 times higher than those for liquid-only flow. The effects of the mixture velocity and the homogeneous void fraction on flow and heat transfer are also studied.     

Pressure drop and liquid holdup for two phase concurrent flow in packed beds

Pressure drop and liquid holdup for two-phase concurrent downward flow in packed beds were correlated for various types of packings by taking into account two hydrodynamic regimes: a poor and a high gas-liquid interaction regime.Foaming and non-foaming systems have been considered.In the poor interaction regime, the pressure drop was calculated as due to the gas flowing in a bed restricted by the presence of the liquid. A correlation valid for a free liquid trickling, modified in order to take into account the effect of the pressure drop, is proposed and used to correlate liquid holdup in the presence of a concurrent gas flow.In the high interaction regime, empirical correlations were proposed for both foaming and non-foaming systems.All the employed correlations fit experimental results from several authors better than those proposed in the literature.     

Effect of Temperature on Controlled Air Oxidation of Plastic and Biomass in a Packed‐Bed Reactor

A packed‐bed reactor was established to study the effect of temperature on the controlled air oxidation (CAO) performance of a mixture of polypropylene and sawdust at a fixed feed gas flow rate. The reactor temperature was varied from 400 to 800 °C. Attention was focused on product distribution, compositions of liquid and gas products, and technical parameters. The chemical composition of the liquid products was analyzed by gas chromatography/mass spectrometry. The results indicated an obvious impact of the temperature on the described parameters. The increase in temperature led to the decrease in solid fraction and a convex shape curve for the gas yield as well as to a decrease of alkanes and alkenes, and favored the generation of oxygen‐containing hydrocarbons. According to criteria of CAO conversion, the optimum temperature in the primary chamber was found to be 700 °C.     

Liquid‐Liquid Stratified Flow through Horizontal Conduits

The stratified configuration is one of the basic and most important distributions during two phase flow through horizontal pipes. A number of studies have been carried out to understand gas‐liquid stratified flows. However, not much is known regarding the simultaneous flow of two immiscible liquids. There is no guarantee that the information available for gas‐liquid cases can be extended to liquid‐liquid flows. Therefore, the present work attempts a detailed investigation of liquid‐liquid stratified flow through horizontal conduits. Gas‐liquid flow exhibits either smooth or wavy stratified orientations, while liquid‐liquid flow exhibits other distinct stratified patterns like three layer flow, oil dispersed in water, and water flow, etc. Due to this, regime maps and transition equations available for predicting the regimes in gas‐liquid flow cannot be extended for liquid‐liquid cases by merely substituting phase physical properties in the equations. Further efforts have been made to estimate the in‐situ liquid holdup from experiments and theory. The analysis considers the pronounced effect of surface tension, and attempts to modify the Taitel‐Dukler model to account for the curved interface observed in these cases. The curved interface model of Brauner has been validated with experimental data from the present work and those reported in literature. It gives a better prediction of liquid holdup in oil‐water flows and reduces to the Taitel‐Dukler model for air‐water systems.