Mechanical stress on suspended particles in two- and three-phase airlift loop reactors and bubble columns

The effect of power input, fluid phase viscosity and solids loading on the mechanical stress on suspended particles was examined. Experiments were carried out in an airlift loop reactor and a bubble column operated in two- and three-phase mode. The disintegration of a shear sensitive floc system was observed with an optical in-line particle system analyser and information about the mechanical stress was obtained by means of mathematical analysis of the raw data. The volumetric power input has been derived to be the governing factor and a linear dependence between volumetric power input and resulting mechanical stress was observed. The addition of a solid phase leads to a drastical change of mechanical stress on the particles with a dominating increase of the stress at high solids loadings. Likewise higher fluid phase viscosity leads to higher mechanical stress on the floc system.     

Effect of contaminants on mass transfer coefficients in bubble column and airlift contactors

In this work, the effects of surface-active contaminants on mass transfer coefficients k_La and k_L were studied in two different bubble contactors. The oxygen transfer coefficient, k_L, was obtained from the volumetric oxygen transfer coefficient, k_La, since the specific interfacial area, a, could be determined from the fractional gas holdup, ε, and the average bubble diameter, d₃₂. Water at different heights and antifoam solutions of 0.5- were used as working media, under varying gas sparging conditions, in small-scale bubble column and rectangular airlift contactors of 6.7 and capacity, respectively. Both the antifoam concentration and the bubble residence time were shown to control k_La and k_L values over a span of almost 400%. A theoretical interpretation is proposed based on modelling the kinetics of single bubble contamination, followed by sudden surface transition from mobile to rigid condition, in accordance with the stagnant cap model. Model results match experimental k_L data within ±30%.     

Influence of configuration on the performance of external loop airlift contactors

Various types of external loop airlift contactors (ELALCs) were examined for their hydrodynamic and mass transfer behavior. The investigation covered a variety of design parameters including the length of connection tubes (L_c), height of riser and downcomer (L_h), and the airlift configurations while maintaining the ratio between downcomer and riser cross sectional area constant at 0.269. The results demonstrated that the behavior of the external loop airlift could be modified by adjusting the design and operating variables. In general, a faster liquid velocity led to a presence of lower gas holdup and gas–liquid mass transfer rate. Increasing L_c and L_h seemed to increase liquid velocity while decreasing the overall gas holdup and the overall volumetric mass transfer coefficient. Empirical correlations for the estimation of the system behavior were finally formulated.     

Bubble characteristics in shallow bubble column reactors

The bubble characteristics have been investigated in an air–water bubble column with shallow bed heights. The effect of bed height, location and the presence of solids on the bubble size, bubble rise velocity and overall and sectional gas holdup are studied over a range of superficial gas velocities. Optimal shallow bed operation relies on the combined entrance and exit effects at the distributor and the liquid bed surface. The gas holdup is found to decrease with an increase in H/D ratio but the effect is diminishing at high H/D ratios. A H/D ratio of 2–4 is found to be suitable for shallow bed operation. The presence of solids causes the formation of larger bubbles at the distributor and the effect is diminishing as the gas velocity is increased.     

Liquid phase mixing in trayed bubble column reactors

The compartmentalization of conventional bubble columns by perforated trays constitutes a very effective method to reduce the liquid backmixing. The effect of tray design and operating conditions on the overall liquid mixing was studied in a bench-scale trayed bubble column. The extent of liquid backmixing in the column was investigated in light of liquid-phase tracer response experiments. In average, a three fold reduction in the liquid backmixing was achieved in the trayed column as compared to the column without the trays. Moreover, the tray open area and the superficial liquid velocity were found to have the strongest effects on the liquid backmixing. The N-CSTR with Backmixing Model was found to match the experimental tracer response curves better than the Axial Dispersion Model.     

气升式环流反应器的特性及应用

综述了气升式环流反应器的特性及其主要影响因素研究,简要介绍了这种反应器的应用情况,并提出了今后研究工作的方向。     

Heat transfer in bubble column and airlift bioreactors: Newtonian and non-Newtonian fermentation broths

A theoretical model has been developed for heat transfer in bubble column and airlift bioreactors, which is applicable for Newtonian and non-Newtonian fermentation media. The proposed model is based on a similarity between heat transfer in gas-sparged pneumatic reactors and turbulent natural convection. The applicability of the proposed model was discussed using a wide range of experimental data, and good agreement was obtained.     

Catalyst mixing in bubble column slurry reactors

The reported experimental data of Pandit and Joshi (1984) on axial and radial steady-state catalyst concentration in a semibatch bubble column slurry reactor is interpreted by the dispersion model. The elliptic partial differential equation with its associated boundary conditions is solved analytically for catalyst concentration by the method of separation of variables. The proposed model adequately fits the experimental data.     

PX氧化鼓泡塔反应器内的TA浓度分布

利用新建的D476鼓泡塔冷模实验装置和沉降—扩散模型对工业鼓泡塔PX氧化反应器内的TA浓度分布进行了实验和数学模拟研究。结果表明,由于PX氧化气速较大,塔内TA浓度接近均匀分布。     

带辐照改性聚丙烯填料的气升式内环流反应器处理废水的研究

应用高能射线辐照技术,在聚丙烯填料表面接枝丙烯酸单体进行改性。将此改性填料应用于气升式内环流反应器中,并对模拟生活废水进行间歇法和连续法处理。实验结果表明,该反应器运行稳定,适应浓度范围广,COD去除率较高,出水COD浓度波动小。     

Compressibility induced bubble size variation in bubble column reactors: Simulations by the CFD–PBE

Bubble column reactors can be simulated by the two fluid model (TFM) coupled with the population balance equation (PBE). For the large industrial bubble columns, the compressibility due to the pressure difference may introduce notable bubble size variation. In order to address the compressibility effect, the PBE should be reformulated and coupled with the compressible TFM. In this work, the PBE with a compressibility term was formulated from single bubble dynamics, the mean Sauter diameters predicted by the compressible TFM coupled with the PBE were compared with the analytical solutions obtained by the ideal gas law. It was proven that the mesoscale formulations presented in this work were physically consistent with the macroscale modeling. It can be used to simulate large industrial plants when the compressibility induced bubble size variation is important.     

Development of support vector regression (SVR)-based correlation for prediction of overall gas hold-up in bubble column reactors for various gas-liquid systems

The objective of this study was to develop a unified data-driven correlation for the overall gas hold-up for various gas-liquid systems using support vector regression (SVR)-based modeling technique. Over the years, researchers have amply quantified the hydrodynamics of bubble column reactors in terms of the overall gas hold-up. In this work, about 1810 experimental points were collected from 40 open sources spanning the years 1965-2007. The model for overall gas hold-up was established as a function of several parameters which include superficial gas velocity, superficial liquid velocity, gas density, molecular weight of gas, sparger type, sparger hole diameter, number of sparger holes, liquid viscosity, liquid density, liquid surface tension, operating temperature, operating pressure and column diameter of the gas-liquid system. For understanding the hold-up behavior, the data used for training the model was grouped into various gas-liquid systems viz., air-water, gas-aqueous viscous liquids, gas-organic liquids, gas-aqueous electrolyte solutions and gas-liquid systems operated over a wide range of pressure. A generalized model established using SVR was evaluated for its performance for various gas-liquid systems. Statistical analysis showed that the proposed generalized SVR-based correlation for overall gas hold-up has prediction accuracy of 97% with average absolute relative error (% AARE) of 12.11%. A comparison of this correlation with the selected system specific correlations in the literature showed that the developed SVR-based correlation significantly gives enhanced prediction of overall gas hold-up.     

Hydrodynamics and mass transfer study of aliphatic alcohols in airlift reactors

Gas holdup and gas–liquid mass transfer coefficient were considered in an external airlift reactor. Air was sparged through some aliphatic alcohols (methanol, ethanol, n-propanol, and n-butanol) with different concentrations (0–1%, v/v). It was observed that gas holdup and mass transfer coefficient increased with increasing the number of carbons in alcohols. Furthermore, an increment in alcohols concentration increased gas holdup and mass transfer coefficient. The same behavior was observed in external and internal loop airlift reactors although gas holdup and mass transfer coefficient values were less than those of internal airlift reactor. According to the experiments, two correlations for gas holdup and mass transfer were developed.     

Hydrodynamic characterization of a needle sparger rectangular bubble column: Homogeneous flow, static bubble plume and oscillating bubble plume

In this work a detailed experimental hydrodynamic characterization of a needle sparger rectangular bubble column has been performed. The liquid velocity profiles and bubble plume oscillation frequency have been measured by means of laser Doppler anemometry (LDA), and the bubble velocity map by particle image velocimetry (PIV). In this way, the influence of the superficial gas velocity, liquid height and aeration pattern on the column flow structure was analysed. A highly uniform upward flow structure with down flow near the walls was obtained by means of a full-length aeration pattern. This flow structure was preserved even for high gas fractions values. The partial-length aeration patterns with the aerated zone (defined as the aerated width divided by the column width) larger than 0.7 provide a bubble plume and two pure liquid vortical structures in the column bottom, although they are static in nature. With aerated zones lower than 0.6, an oscillating bubble plume is obtained. A non-dimensional analysis of bubble plume oscillation frequency shows a dependence of bubble plume behaviour with the aerated zone. In this way, two different types of bubble plume oscillations, namely confined bubble plume oscillation and free bubble plume oscillation, are introduced and analysed.     

Investigation of low-temperature methanol synthesis in a bubble column slurry reactor with a flash column

Reaction performance of a CuCr/CH₃ONa catalyst for the low-temperature methanol synthesis was examined in a bubble column slurry reactor with a flash column (BCSR/FC). The BCSR/FC was operated at 4.5 ± 0.2 MPa/110–120 °C for BCSR and 0.4 ± 0.1 MPa/80–90 °C for FC, although fluctuation of operation parameters was larger. Syngas conversion decreased from 71.0% to 19.8% during the operation test in 100 h, which was attributed to consumption of CH₃ONa and a negative effect of the emulsifier OP-10 used.     

CFD modeling of slurry bubble column reactors for Fisher-Tropsch synthesis

Industrial bubble column reactors for Fischer-Tropsch (FT) synthesis include complex hydrodynamic, chemical and thermal interaction of three material phases: a population of gas bubbles of different sizes, a liquid phase and solid catalyst particles suspended in the liquid. In this paper, a CFD model of FT reactors has been developed, including variable gas bubble size, effects of the catalyst present in the liquid phase and chemical reactions, with the objective of predicting quantitative reactor performance information useful for design purposes. The model is based on a Eulerian multifluid formulation and includes two phases: liquid-catalyst slurry and syngas bubbles. The bubble size distribution is predicted using a Population Balance (PB) model. Experimentally observed strong influence of the catalyst particles concentration on the bubble size distribution is taken into account by including a catalyst particle induced modification of the turbulent dissipation rate in the liquid. A simple scaling modification to the dissipation rate is proposed to model this influence in the PB model. Additional mass conservation equations are introduced for chemical species associated with the gas and liquid phases. Heterogeneous and homogeneous reaction rates representing simplified FT synthesis are taken from the literature and incorporated in the model.Hydrodynamic effects have been validated against experimental results for laboratory scale bubble columns, including the influence of catalyst particles. Good agreement was observed on bubble size distribution and gas holdup for bubble columns operating in the bubble and churn turbulence regimes. Finally, the complete model including chemical species transport was applied to an industrial scale bubble column. Resulting hydrocarbon production rates were compared to predictions made by previously published one-dimensional semi-empirical models. As confirmed by the comparisons with available data, the modeling methodology proposed in this work represents the physics of FT reactors consistently, since the influence of chemical reactions, catalyst particles, bubble coalescence and breakup on the key bubble-fluid drag force and interfacial area effects are accounted for. However, heat transfer effects have not yet been considered. Inclusion of heat transfer should be the final step in the creation of a comprehensive FT CFD simulation methodology. A significant conclusion from the modeling results is that a highly localized FT reaction rate appears next to the gas injection region when the syngas flow rate is low. As the FT reaction is exothermal, it may lead to a highly concentrated heat release in the liquid. From the design perspective, the introduction of appropriate heat removal devices may be required.     

Flow regime, hydrodynamics, floc size distribution and sludge properties in activated sludge bubble column, air-lift and aerated stirred reactors

This paper presents a comparative study how reactor configuration, sludge loading and air flowrate affect flow regimes, hydrodynamics, floc size distribution and sludge solids-liquid separation properties. Three reactor configurations were studied in bench scale activated sludge bubble column reactor (BCR), air-lift reactor (ALR) and aerated stirred reactor (ASR). The ASR demonstrated the highest capacity of gas holdup and resistance, and homogeneity in flow regimes and shearing forces, resulting in producing large numbers of small and compact flocs. The fluid dynamics in the ALR created regularly directed recirculation forces to enhance the gas holdup and sludge flocculation. The BCR distributed a high turbulent flow regime and non-homogeneity in gas holdup and mixing, and generated large numbers of larger and looser flocs. The sludge size distributions, compressibility and settleability were significantly influenced by the reactor configurations associated with the flow regimes and hydrodynamics.     

Influence of coalescence behaviour of the liquid and of gas sparging on hydrodynamics and bubble characteristics in a bubble column

This experimental study is aimed at investigating the effect of liquid phase properties and gas distribution on bubble and hydrodynamic characteristics in bubble columns. With the various measuring techniques used, systematic measurements of bubble size, velocity and frequency and gas hold-up are possible. Bubble size distribution and shape factors which are rarely found in literature, are also available. Water–alcohol solutions are used to simulate the behaviour of industrial non-coalescing organic mixtures. The experimental results obtained with three different spargers in the coalescence inhibiting solutions are compared with data on standard coalescing air–water system. Evolutions of bubble characteristics and gas hold-up have been interpreted successfully by considering the simultaneous influence of the hydrodynamic regime of the gas–liquid flow and of the operating regime of the distributor. It has also been put into evidence that bubble frequency measurements are good tools to evaluate distributor efficiency. The influence of the distributor has been shown to be enhanced in non-coalescing media. Bubble shape and bubble size distributions are dramatically modified by addition of minute quantities of alcohol in water. Bimodal distributions can be observed even in the homogeneous regime with orifice nozzle spargers.     

The selective hydrogenation of butyne-1,4-diol by supported palladiums: a comparative study on slurry, fixed bed, and monolith downflow bubble column reactors

The present study was carried out to asses performance of a Pd-monolith downflow bubble column (DBC) reactor, and compare it with that of the slurry and the fixed bed DBC. The selective hydrogenation of butyne-1,4-diol to cis-2-butene-1,4-diol over palladium catalyst was chosen as a model reaction. In principle, the monolith DBC allowed the reaction to take place under kinetic control regime. Comparison with DBC employing 5% Pd/C powder and 1% Pd-on-Raschig ring catalysts revealed a better performance of the monolith DBC (1% Pd loading) with advantage of smaller reaction volume and intensified reaction rate. In the monolith DBC, improved hydrogen transport was possible, as the interface between bubbles and the channel wall was very thin, thus, the length of the diffusion path was very short. In addition, the interfacial surface area at both gas–liquid and liquid–solid interface in the monolith was also very high. The reaction kinetics was well represented by the Langmuir–Hinshelwood mechanism. As an alternative to conventional three-phase reactors, the monolith DBC was simple due to its inherent characteristic operation and no specially designed device.