Axial mixing and mass transfer investigation in a pulsed packed liquid–liquid extraction column using plug flow and axial dispersion models

In this research work, the volumetric overall mass transfer coefficient based on continuous-phase (K_oca) and axial dispersion coefficients of phases (E_c, E_d) in a pilot Pulsed Packed Liquid Extraction Column (PPLEC) have been studied using plug flow model (PFM) and axial dispersion model (ADM). Experiments have been carried out using standard systems of water/acetone/toluene and water/acetone/n-butyl–acetate. Values of K_oca evaluated by ADM are greater than those of PFM by about 20% indicating that the axial mixing lowers the performance of PPLEC. It was found that the drop-size distribution is the main cause of the axial mixing in PPLEC. Increase in dispersed phase flow rate (Q_d), increases all K_oca, E_d and E_c and the minimum values of both E_d and E_c and the maximum values of K_oca are in pulse intensity ranges of 0.8–1 cm/s. Finally, three empirical correlations are proposed for the prediction of these parameters which are in good agreement with the experimental data.     

Facile synthesis of graphene oxide in a Couette–Taylor flow reactor

A practical approach to bulk-scale graphene-based materials is critically important for their use in the industrial applications. Here, we describe a facile method to prepare graphite oxide (GO) using a Couette–Taylor flow reactor for the oxidation of bulk graphite flakes. We found that the turbulent Couette–Taylor flow in the reactor could be engineered to result in the efficient mixing and mass transfer of graphite and oxidizing agents (KMnO₄ and H₂SO₄), thereby improving the efficiency of graphite into GO. As compared to the standard Hummers’ method, higher fraction of a single- and few-layer graphene oxide (G-O) can be yielded in a dramatically shortened reaction time, by optimizing the processing parameters, we have shown that ∼93% of G-O yield could be achieved within 60 min of reaction time. This method also allowed for the in-situ functionalization of G-O with metal oxide nanoparticles to give a nanoparticle-decorated G-O hybrid material. Our method for facile and large-scale production of graphite oxide may find utility in a range of applications including energy storage, composites and supporting frameworks of catalyst.     

CFD simulation of Taylor–Couette flow in scraped surface heat exchanger

The flow between two concentric cylinders which is termed as Taylor–Couette flow has been studied in scraped surface heat exchanger with and without blades. Shear rate in annular flow with and without blades was measured by Dumont et al. (2000a) using electrochemical method and determined the onset of Taylor vortices at specific Taylor number in both cases for Newtonian flow. CFD simulations have been carried out to determine the transition zone from laminar Couette flow to Taylor vortex flow using the same geometry for which Dumont et al. (2000a) had carried out the experiments. The Reynolds stress model (RSM) and k–? model are used for Taylor vortex flow (Ta > 300) to characterize the flow pattern in annular flow and SSHE respectively. The aim of the present work is to analyze the effect of rotating scraper on the existing flow patterns in simple annular flow using CFD simulations.     

Experimental investigation on solid dispersion,power consumption and scale-up in moderate to dense solid–liquid suspensions

Detailed particle concentration distribution in dense solid–liquid suspension was measured by means of fiber optic probes. The effect of solid loading, impeller speed, and impeller type and clearance was investigated. Results were compared with modeling approaches to show the accuracy of sedimentation–dispersion model and its capability to describe complex phenomena taking place in dense liquid–solid mixing systems. Variation of power numbers by changing impeller clearance and solid loading were also investigated. It was shown that the impeller power number for a slurry system exhibited different trends in a moderate or dense liquid–solid system. In addition, scale-up rules to achieve the same level of homogeneity on a large scale as the laboratory scale were evaluated.     

Experimental investigation and CFD simulation of liquid–solid–solid dispersion in a stirred reactor

For understanding the monosodium aluminate hydrate crystallization from the supersaturated aluminate solution containing red mud as the leaching liquor of bauxite, the liquid–solid–solid dispersion of a simulant system, i.e. glycerite, red mud and sand, in a stirred reactor has been experimentally investigated as well as simulated using computational fluid dynamics model (CFD) for the first time. The computational model is based on the Eulerian multi-fluid model along with RNG k–ε turbulence model, where Syamlal–obrien-symmetric drag force model (Syamlal, 1987) of the inter-phase momentum transfer between two dispersed solid phases is taken into account. A good agreement is obtained between the experimental data of solid distributions and the simulation results in the flow fields of liquid–solid–solid as well as liquid–solid systems. The solid suspension qualities of both liquid–solid and liquid–solid–solid systems in the stirred reactors with and without draft tube were also studied in detail based on mixing time, the standard deviation of solid concentration proposed by Bohnet and Niesmak (1980), the flow pattern and power number. The influence of the interaction between two dispersed solid phases on the suspension of red mud is found significantly greater than that of sand. The holdup of sand below the impeller is considerably larger than that above the impeller and the red mud dispersion approaches homogeneous in the reactor. The mixing time of liquid–solid–solid suspension is longer than that of liquid–solid suspension under the same conditions, and the mixing times of both systems in the stirred reactor with draft tube are longer than that in the reactor without draft tube. Furthermore, the distributions of sand and red mud in the reactor with draft tube were found less homogeneous than those without draft tube in most cases.     

Experimental and numerical study of stratified viscous oil–water flow

Stratified two-phase flows of oil and water are important to the energy industry, and models capable of predicting this type of flow are primordial. Many studies focus on fluids with low viscosity, but a high viscosity oil in the mixture significantly changes its behavior. We gathered experimental data of pressure drop, volumetric fractions, and flow-pattern data of a stratified liquid–liquid flow with high viscosity ratio. In addition, a wire-mesh sensor provided tomographic views of the flow. The data were compared with computational fluid dynamics (CFD) models using OpenFOAM and a one-dimensional model. CFD simulations used an interface capturing method, and turbulence damping was introduced to avoid high eddy viscosity at the interface region. Reynolds Average Navier–Stokes and large eddy simulations were used to account for turbulence, and they showed significant differences. The comparisons showed good overall results for pressure drop, volumetric fractions, and phase distributions between CFD and experiments.     

Experimental investigation on gas–liquid flow,heat and mass transfer characteristics in a dual-contact-flow absorption tower

As a kind of chemical reactor, the dual-contact-flow absorption tower has been widely used for SO₂ absorption in recent years. However, studies on heat transfer characteristics of the absorber have been rarely carried out. There is also lack of an integrated partition map of flow pattern in the dual-contact-flow absorption tower. In this paper, the gas–liquid flow, heat and mass transfer characteristics in the dual-contact-flow absorption tower have been experimentally investigated. Direct observation, probability density function (PDF) and power spectral density function (PSD) methods are comparatively adopted in the flow pattern analysis. The partition map of flow pattern in the dual-contact-flow absorption tower is obtained through integrating a large quantity of experimental data. In addition, empirical formulas of both heat and mass transfer performances have been developed. Application of empirical formulas has also been stated. The research results obtained in the present study can provide guidance for estimating the practical application performance.     

Process intensification of continuous starch hydrolysis with a Couette–Taylor flow reactor

Starch gelatinization and enzymatic hydrolysis was carried out in a continuous Couette–Taylor flow reactor with a water jacket. The degree of gelatinization and the concentration of reducing sugars produced via enzymatic saccharification were evaluated by varying operational variables: rotation speed of an inner cylinder, initial concentration of starch and reaction temperature. At the initial concentration of the starch suspension, 50 kg m⁻³, starch saccharification proceeded sufficiently even at low rotation speed of the inner cylinder and saccharification temperature. At the higher initial concentration, 100 and 150 kg m⁻³, a higher rotation speed of the inner cylinder and temperature of the saccharification section were required to obtain sufficient starch saccharification. Even in the case of C₀ = 100 and 150 kg m⁻³, the more reducing sugar was obtained by choosing an adequate rotation speed of the inner cylinder and a reaction temperature.     

Effect of hydrodynamic heterogeneity on micromixing intensification in a Taylor–Couette flow reactor with variable configurations of inner cylinder

Effect of hydrodynamic heterogeneity on micromixing intensification in a Taylor–Couette flow (TC) reactor with variable configurations of inner cylinder has been investigated by adoption of a parallel competing iodide-iodate reaction system. Two types of inner cylinder, circular inner cylinder and lobed inner cylinder (CTC and LTC), were used to generate hydrodynamic heterogeneity, focusing on the effects of the Reynolds number, the acid concentration, and the feeding time on the micromixing performance. Segregation index (Xs) was employed to evaluate the micromixing efficiency. It is revealed that Xs decreases with the increase of Reynolds number and feeding time but increases with the increase of acid concentration for both the CTC and LTC. However, the LTC does present a better micromixing performance at various operating conditions than that of the CTC as affirmed by both the experimental and computational fluid dynamics simulation results.     

Experimental investigation of liquid–liquid flow in an inclined pipe using dimensionless numbers

Two-phase flow is a common phenomenon in the energy industry, where flow patterns significantly affect heat transfer and pressure drop in different systems. However, there is no unique or comparable flow map because of its dependency on dimensional parameters. Therefore, an analysis using dimensionless numbers makes the results comprehensive. To do so, a series of liquid–liquid flow experiments (1296 experiments) were conducted in a transparent pipe at the different velocities of the phases. The flow patterns were captured using a high-speed camera. The experiments were performed at eight different inclinations within the range of −20 to +20 degrees. Six flow patterns are observed at different inclinations; stratified flow with mixing at the interface (STMI), dispersion of water in oil (Dw/o), dispersion of oil in water (Do/w), dual continuous (DC), slug, and wavy stratified (WST), where the first five flow patterns are presented in the upward flow and the two last flow patterns disappear in some of the downward flow. The pattern of boundaries for each flow pattern in the upward flow shows dependency on inclination, while in the downward flow condition, a rather general format can be applied to most of the patterns. The analysis illustrates that gravity and buoyancy forces are the dominating forces in the system compared to other forces, such as viscous, inertia, and interfacial tension, which are due to the inclination of the pipe.     

Experimental study on gas–liquid dispersion and mass transfer in shear-thinning system with coaxial mixer

The effects of impeller type, stirring power, gas flow rate, and liquid concentration on the gas–liquid mixing in a shear-thinning system with a coaxial mixer were investigated by experiment, and the overall gas holdup, relative power demand, and volumetric mass transfer coefficient under different conditions were compared. The results show that, the increasing stirring power or gas flow rate is beneficial in promoting the overall gas holdup and volumetric mass transfer coefficient, while the increasing system viscosity weakens the mass transfer in a shearing–thinning system. Among the three turbines, the six curved-blade disc turbine (BDT-6) exhibits the best gas pumping capacity; the six 45° pitched-blade disc turbine (PBDT-6) has the highest volumetric mass transfer coefficient at the same unit volume power.     

Mixing and recirculation characteristics of gas–liquid Taylor flow in microreactors

The effects of operating parameters (capillary and Reynolds numbers) and microchannel aspect ratio (α=w/h=[1;2.5;4]$\alpha =w/h=[1;2.5;4]$) on the recirculation characteristics of the liquid slug in gas–liquid Taylor flow in microchannels have been investigated using 3-dimensional VOF simulations. The results show a decrease in the recirculation volume in the slug and an increase in recirculation time with increasing capillary number, which is in good agreement with previous results obtained in circular and square geometries (Thulasidas et al., 1997). In addition, increasing the aspect ratio of the channel leads to a slight decrease in recirculating volumes but also a significant increase in recirculation times.     

On axial dispersion in packed beds with fluid flow: Über die axiale dispersion in durchströmten festbetten

In the present work a theoretical analysis of the dependence between the axial dispersion of mass and the flow nonuniformity in packed beds is given. Three types of flow nonuniformity are defined: micro-, meso- and macroscopical. In order to describe the influence of microscopical flow nonuniformity on axial dispersion in packed beds the flow channels are approximated by equal-sized cylindrical capillaries. A step function is used for the velocity profile and the fluid in the outer region of each capillary is assumed to be stagnant. The relationship derived in this manner can describe most results of tracer experiments well; above all, it helps in understanding the differences observed between dispersion of gases and dispersion of liquids. Anomalously high dispersion coefficients, obtained during dispersion of gases through beds of fine-grained particles, are attributed to the mesoscopical flow nonuniformity and are described in a model. Finally, the dependence between macroscopical flow nonuniformity and axial dispersion in packed beds is discussed. It turns out that the influence of channelling on axial dispersion is rather insignificant. In this manner, the results of tracer experiments can be brought into accordance with velocity profiles proposed in the literature. The essential differences between the present analysis and previous works are pointed out.     

Bubble lengths in the gas–liquid Taylor flow in microchannels

Experimental results of measurements of the bubble and slug lengths in Taylor (slug) flow are presented. The experiments were carried out using 3 different straight microchannels (microreactor with square cross-section made of polydimethyloxosilane (PDMS); microreactor with circular cross-section made of glass; microreactor with rectangular cross-section made of polyethylene terephthalate modified by glycol (PETg)) and 4 different liquids (water, ethanol propanol and heptane). The results have been compared with the available literature correlations. It is concluded, that the values obtained from the correlation proposed by Laborie et al. [Laborie, S., Cabassud, C., Durant-Bourlier, L., Laine, J.M., 1999. Characterization of gas–liquid two-phase flow inside capillaries. Chem Eng Sci 54, 5723–5735] do not agree with the results of measurements, while the agreement of these results with the predictions obtained using the correlation proposed by Qian and Lawal [Qian, D., Lawal, A., 2006. Numerical study on gas and liquid slugs for Taylor flow in a T-junction microchannel. Chem Eng Sci 61, 7609–7625] is good. New, corrected values of the pre-exponential constant and the exponents in the Qian and Lawal [Qian, D., Lawal, A., 2006. Numerical study on gas and liquid slugs for Taylor flow in a T-junction microchannel. Chem Eng Sci 61, 7609–7625] correlation are proposed.     

Hydrodynamics and mass transfer in a Couette–Taylor bioreactor for the culture of animal cells

A Couette–Taylor bioreactor device, commercialized by Synthecon for the culture of tissues, can exhibit interesting hydrodynamics and mass-transfer characteristics that could be well suited for the culture of animal cells in suspension. This is investigated through hydrodynamics and mass-transfer study on a plexiglass copy of the existing commercial equipment. Results of these studies show the potential of the Synthecon bioreactor for the culture of animal cells in suspension. The Synthecon bioreactor is then bought and actually used for the culture of CHO cells in suspension. First results confirm the approach developed on the plexiglass copy.     

Flow patterns and gas fractions of air–oil and air–water flow in pipe bends

An experimental study of two-phase flow in a 180° pipe bends with 0.016, 0.022 and 0.03 m and the curvature radii of 0.11, 0.154, 0.21 m, respectively have been carried out. The experiments were conducted under the input superficial phase velocity: air from 0.038 to 5.4 m s⁻¹, water from 0.018 to 0.92 m s⁻¹ and oil from 0.014 to 0.92 m s⁻¹. The conducted research involved the observation of the forming flow patterns and determination of average volumetric in situ gas fraction. On the basis of the results of experimental flow map was created for gas–liquid flow and a method of calculating gas fractions was established.     

A study on periodic boundary condition in direct numerical simulation for gas–solid flow

Direct numerical simulation(DNS) of gas–solid flow at high resolution has been carried out by coupling the lattice Boltzmann method(LBM) for gas flow and the discrete element method(DEM) for solid particles. However,the body force periodic boundary condition(FPBC) commonly used to cut down the huge computational cost of such simulation has faced accuracy concerns. In this study, a novel two-region periodic boundary condition(TPBC) is presented to remedy this problem, with the flow driven in the region with body force and freely evolving in the other region. With simulation cases for simple circulating fluidized bed risers, the validity and advantages of TPBC are demonstrated with more reasonable heterogeneity of the particle distribution as compared to the corresponding case with FPBC.     

Characteristics of liquid slugs in gas–liquid Taylor flow in microchannels

The hydrodynamics of liquid slugs in gas–liquid Taylor flow in straight and meandering microchannels have been studied using micro Particle Image Velocimetry. The results confirm a recirculation motion in the liquid slug, which is symmetrical about the center line of the channel for the straight geometry and more complex and three-dimensional in the meandering channel. An attempt has also been made to quantify and characterize this recirculation motion in these short liquid slugs (L_s/w<1.5) by evaluating the recirculation rate, velocity and time. The recirculation velocity was found to increase linearly with the two-phase superficial velocity U_TP. The product of the liquid slug residence time and the recirculation rate is independent of U_TP under the studied flow conditions. These results suggest that the amount of heat or mass transferred between a given liquid slug and its surroundings is independent of the total flow rate and determined principally by the characteristics of the liquid slug.     

Study of cell seeding on porous poly(d,l-lactic-co-glycolic acid) sponge and growth in a Couette–Taylor bioreactor

In this study, porous poly(d,l-lactic-co-glycolic acid) (PLGA) sponges were fabricated by using a solvent-free supercritical CO₂ gas-foaming technique. The sponges were then used as three dimensional scaffolds to culture rat bone marrow stroma (rBMS) cells. The rBMS cells were seeded on the scaffolds using a rocking shaker in three directions with different shaking speeds and times. The amount of cells attached onto the polymer sponges increased with the increase of initial cells amounts. A saturation level [Cell_{seeded max}] was achieved when the initial seeded cells were above 6×10⁴. The seeding curved followed closely to a mathematical model through which [Cell_{seeded max}] and seeding affinity (k) can be calculated. A Couette–Taylor bioreactor was subsequently used to culture the cell-sponge constructs. The Taylor vortex flow patterns generated in the bioreactor were characterized by particle imaging velocimetry (PIV). Computation fluid dynamics simulations were performed to reconfirm the vortex flow characteristics and determine the distribution of shear rate and shear stress quantitatively. The results indicated that moderate shear stresses (0.02–0.19 Pa) generated in the bioreactor improved the proliferation of rBMS cells to around 1.3 times of the static control with well maintained calcium deposition ability of the cells. Relative larger shear stresses (0.24 Pa) helped to improve the calcium deposition ability of the cells but inhibited their proliferations. Larger shear stress (>0.24 Pa) inhibited the proliferation of the cells as well as weakened the ability of cell membrane to preserve calcium ions.     

Experimental investigation on multiscale hydrodynamics in a novel gas–Liquid–Solid three phase jet-Loop reactor

Multiphase flow hydrodynamics in a novel gas–liquid–solid jet-loop reactor (JLR) were experimentally investigated at the macroscales and mesoscales. The chord length distribution was measured by an optical fiber probe and transformed for bubble size distribution through the maximum entropy method. The impacts of key operating conditions (superficial gas and liquid velocity, solid loading) on hydrodynamics at different axial and radial locations were comprehensively investigated. JLR was found to have good solid suspension ability owing to the internal circulation of bubbles and liquid flow. The gas holdup, axial liquid velocity, and bubble velocity increase with gas velocity, while liquid velocity has little influence on them. Compared with the gas–liquid JLRs, solids decrease the gas holdup and liquid circulation, reduces the bubble velocity and delays the flow development due to the enhanced interaction between bubbles and particles (Stokes number >1). This work also provides a benchmark data for computational fluid dynamics (CFD) model validation. © 2019 American Institute of Chemical Engineers AIChE J, 65: e16537, 2019