Gas‐Liquid Mass Transfer Rates and Impeller Power Consumptions for Industrial Vessel Design

Volumetric mass transfer coefficients (k_La) and power input (P) are often the key parameters in the design of gas‐liquid contactors. However, due to the limitations of most measurement methods, there is a lack of reliable data for predicting k_La for non‐coalescent batches under high energy dissipation rates. Accurate k_La and P correlations are proposed. The reliability of the correlations is ensured by using experimental data from a wide range of process conditions conducted in multiple‐impeller vessels of both laboratory scale and pilot scale, and including both non‐coalescent and coalescent batches. Applying the proposed correlations, the scale‐up and optimization of industrial vessels can be performed more accurately.     

Power Input Prediction in Agitated Gas‐Liquid Contactors with Non‐coalescent Batch

Volumetric mass transfer coefficients, k_La, just as power input are considered as essential parameters for mechanically agitated gas‐liquid contactors in relation to their optimization and design. The knowledge of power input is crucial for the prediction of other mass transfer characteristics. A power input correlation is created for the industrial design of the process with a non‐coalescent batch that would be appropriate for a broad range of operational conditions. The recommended resulting correlation is able to predict the power input for impellers in industrial‐scale design for a significant scope of operational conditions.     

Influence of Spacing of Multiple Impellers on Power Input in an Industrial‐Scale Aerated Stirred Tank Reactor

Despite the fact that aerated stirred tank reactors are widely used in industry and often studied, their design and scale‐up still remains challenging. Especially the specific power input is a crucial and geometry‐dependent scale‐up parameter, usually calculated with the dimensionless power number Po. Within the scope of this study, the power number is measured for different stirrer types and configurations in a laboratory and an industrial‐scale aerated stirred tank reactor. Good agreements to literature are found for the unaerated case for the two‐stage stirrer configurations at different stirrer spacing for both scales. By literature only the aerated case in the laboratory scale can be predicted. Scale‐up of an aerated industrial‐scale reactor is challenging because of a specific influence of the aeration. In case of a three‐stage Rushton configuration, an asymmetrical distribution of the stirrers should be preferred to ensure a high power number as well as good power performance under aerated conditions.     

Salting‐out crystallisation using NH3 in a laboratory‐scale gas lift reactor

Despite the advantages offered by gas lift reactors with respect to high gas–liquid mass transfer with a low energy input, their acceptance in the crystallisation field has been slow, especially on an industrial scale. Potassium chloride, potassium sulfate, and magnesium chloride hexammoniate (MgCl₂·6NH₃) were crystallised in a laboratory‐scale gas lift crystalliser by salting‐out using ammonia gas. Ammonia mass transfer rates were calculated for each test. To achieve maximum crystal growth, the gas rate in these reactors needs to be optimised for each crystallising system to achieve sufficient gas mass transfer as well as providing sufficient crystal slurry agitation.     

Study of Hydrodynamics,Mixing and Gas‐Liquid Mass Transfer in a Split‐Rectangular Airlift Reactor

Global hydrodynamic characteristics, liquid mixing and gas‐liquid mass transfer for a 63 L split‐rectangular airlift reactor were studied. Correlations for gas holdup and overall liquid circulation velocity were derived for the air‐water system as a function of the specific power input; these were compared to data and correlations for reactor volumes between 4.7 L and 4600 L. A partial recirculation of small bubbles in the riser was observed when U_gr > 0.03 m/s, which was attributed to the use of a single‐orifice nozzle as the gas phase distributor. The dimensionless mixing time and the overall axial dispersion coefficient were nearly constant for the range of gas flow rates studied. However, values of K_L/d_B were greater than those reported in previous studies and this is caused by the partial recirculation of the gas phase in the riser. While scale effects remain slight, the use of a gas distributor favouring this partial recirculation seems adequate for mass transfer in split‐rectangular airlift reactors.     

One‐Dimensional Modeling and Simulation of Bubble Column Reactors

Reactor models that feature a practical way to design bubble columns on the semi‐industrial or even industrial scale have been published only rarely in the usual scientific literature. Creating a one‐dimensional model in the equation‐oriented simulation software ASPEN Custom Modeler? (ACM), one can reach a compromise between model precision and modeling – i.e. computational power – based on correlations selected specifically for the application in question. The model quantitatively describes, with sufficient accuracy, the processes in a bubble column reactor. The paper discusses investigations for designing a pilot plant reactor for hydrogenating 2‐ethylhexanal as an example of its application. Geometry and operating conditions were optimized, and the results are shown in the form of spatially resolved reaction and temperature profiles.     

Performance Evaluation of Two High‐Shear Impellers in an Unbaffled Stirred Tank

High‐shear impellers (HSIs) are mixers used in industrial stirred tanks to incorporate powders into liquids and break down particle agglomerates. A detailed numerical study of two commercial ring‐style HSIs of laboratory scale was carried out and their performance was compared with the Rushton turbine (RT). It was found that power and pumping numbers or their ratio cannot be simply connected for properly selecting an impeller in applications where highly localized viscous dissipation is desirable. The ratio of the average viscous dissipation in the impeller swept volume to the mean in the entire volume at two constant values of power input turned out to be lower for HSIs compared to that evaluated for RT. However, at higher power input, the dimensionless average viscous dissipation in the blade swept volume was found to be similar for the HSI of two rings and the RT, corroborating the high local viscous dissipation of this HSI when operated at higher speeds.     

Gas Chromatographic Enantioseparation of Fluorinated Anesthetics: Single‐Column Performance and Scale‐up Estimation

Results of a study devoted to provide the pure enantiomers of isoflurane and desflurane from racemic mixtures using gas chromatography are presented. For that purpose, a cyclodextrin‐based selector described in earlier work was immobilized on porous glass beads. The adsorption isotherms were determined and applied to predict operating parameters which provide the highest possible productivity of the separation. The analysis included evaluation of the performance of larger columns applying simplifying scale‐up considerations. Using repetitive batches, the method can provide per day with a laboratory scale column approximately 1 g pure enantiomer. Selected model predictions were validated experimentally.     

Filtered two‐fluid models of fluidized gas‐particle flows: New constitutive relations

New constitutive relations for filtered two‐fluid models (TFM) of gas‐particle flows are obtained by systematically filtering results generated through highly resolved simulations of a kinetic theory‐based TFM. It was found in our earlier studies that the residual correlations appearing in the filtered TFM equations depended principally on the filter size and filtered particle volume fraction. Closer inspection of a large amount of computational data gathered in this study reveals an additional, systematic dependence of the correction to the drag coefficient on the filtered slip velocity, which serves as a marker for the extent of subfilter‐scale inhomogeneity. Furthermore, the residual correlations for the momentum fluxes in the gas and particle phases arising from the subfilter‐scale fluctuations are found to be modeled nicely using constitutive relations of the form used in large‐eddy simulations of single‐phase turbulent flows. © 2013 American Institute of Chemical Engineers AIChE J, 59: 3265–3275, 2013     

H2 rich product gas by steam gasification of biomass with in situ CO2 absorption in a dual fluidized bed system of 8 MW fuel input

The steam gasification of solid biomass by means of the absorption enhanced reforming process (AER process) yields a high quality product gas with increased hydrogen content. The product gas can be used for a wide range of applications which covers the conventional combined heat and power production as well as the operation of fuel cells, the conversion into liquid fuels or the generation of synthetic natural gas and hydrogen. On the basis of a dual fluidized bed system, steam gasification of biomass is coupled with in situ CO₂ absorption to enhance the formation of hydrogen. The reactive bed material (limestone) used in the dual fluidized bed system realizes the continuous CO₂ removal by cyclic carbonation of CaO and calcination of CaCO₃. Biomass gasification with in situ CO₂ absorption has been substantially proven in pilot plant scale of 100 kW fuel input. The present paper outlines the basic principles of steam gasification combined with the AER process the investigations in reactive bed materials, and concentrates further on the first time application of the AER process on industrial scale. The first time application has been carried out within an experimental campaign at a combined heat and power plant of 8 MW fuel input. The results are outlined with regard to the process conditions and achieved product gas composition. Furthermore, the results are compared with standard steam gasification of biomass as well as with application of absorption enhanced reforming process at pilot plant scale.     

Scale‐up and Spouting of Two‐Dimensional Beds

The objective of this paper is to present an analysis on the scale‐up procedure of two‐dimensional spouted beds. The task was carried out with three different beds measuring 0.15, 0.30 and 0.80 in width. The conditions of scale‐up were studied through geometrical similitude analysis. Some parameters of scale were adimensionalised, tested and validated in order to propose relationships capable of predicting values of dependent properties. Those relationships should be followed in a prototype of an equipment of industrial scale. The study permitted the development of correlations to predict values of maximum pressure drop, minimum spout velocity and maximum height of spouting.     

Mass transfer and hydrodynamic characteristics in a co‐current downflow contacting column

Hydrodynamic and mass transfer characteristics of water–air system in a co‐current downflow contacting column (CDCC) were studied for various nozzle diameters at different superficial gas velocities and liquid re‐circulation rates. Gas hold‐up and liquid‐side mass transfer coefficient increased with increasing superficial gas velocity and liquid flow rate but decreased with increasing nozzle diameter. It is shown that correlations developed, which are based on liquid kinetic power per liquid volume present in the column, and superficial gas velocity explains gas hold‐up and the mass transfer coefficient within an error 20% for all gas and liquid flow rates and nozzle diameters used. The constants of correlations for gas hold‐up and mass transfer coefficient were found to be considerably different from other gas–liquid contacting systems. © 2003 Society of Chemical Industry     

Impact of gravity on the bubble‐to‐pulse transition in packed beds

A model based on two‐phase volume‐averaged equations of motion is proposed to examine the gravity dependence of the bubble‐to‐pulse transition in gas‐liquid cocurrent down‐flow through packed beds. As input, the model uses experimental correlations for the frictional pressure drop under both normal gravity conditions and in the limit of vanishing gravity, as well as correlations for the liquid‐gas interfacial area per unit volume of bed in normal gravity. In accordance with experimental observations, the model shows that, for a given liquid flow, the transition to the pulse regime occurs at lower gas‐flow rates as the gravity level or the Bond number is decreased. Predicted transition boundaries agree reasonably well with observations under both reduced and normal gravity. The model also predicts a decrease in frictional pressure drop and an increase in total liquid holdup with decreasing gravity levels. © 2013 American Institute of Chemical Engineers AIChE J 60: 778–793, 2014     

Reactor Modeling of Gas‐Phase Polymerization of Ethylene

A model is developed for evaluating the performance of industrial‐scale gas‐phase polyethylene production reactors. This model is able to predict the properties of the produced polymer for both linear low‐density and high‐density polyethylene grades. A pseudo‐homogeneous state was assumed in the fluidized bed reactor based on negligible heat and mass transfer resistances between the bubble and emulsion phases. The nonideal flow pattern in the fluidized bed reactor was described by the tanks‐in‐series model based on the information obtained in the literature. The kinetic model used in this work allows to predict the properties of the produced polymer. The presented model was compared with the actual data in terms of melt index and density and it was shown that there is a good agreement between the actual and calculated properties of the polymer. New correlations were developed to predict the melt index and density of polyethylene based on the operating conditions of the reactor and composition of the reactants in feed.     

Hydrodynamics in a pilot‐scale cocurrent trickle‐bed reactor at low gas velocities

Hydrodynamic data obtained from laboratory‐scale trickle‐beds often fail to accurately represent industrial‐scale systems with high packing aspect ratios and column‐to‐particle diameter ratios. In this study, pressure drop, liquid holdup, and flow regime transition were investigated in a pilot‐scale trickle‐bed column of 33 cm ID and 2.45 m bed height packed with 1.6 mm × 8.4 ± 1.4 mm cylindrical extrudates for air‐water mass superficial velocities of 0.0023 – 0.094 kg/m²s and 4.5 – 45 kg/m²s, respectively, at atmospheric pressure. Significant deviation was observed from pressure drop and liquid holdup correlations at low liquid flows rates, corresponding to gravity‐driven flow limit. Likewise, liquid saturation is overestimated by correlations at high liquid flow rates, owing to significantly reduced wall effects. Lastly, trickle‐to‐dispersed bubble flow and trickle‐to‐pulsing flow regime transitions are reported using a combination of visual observations and analysis of the magnitude of local pressure fluctuations within the column. © 2018 American Institute of Chemical Engineers AIChE J, 64: 2560–2569, 2018     

Correlation between processing conditions and fiber breakage during compounding of glass fiber‐reinforced polyamide

The inter‐relationship between processing conditions and fiber breakage has been studied for glass fiber‐reinforcedpolyamide 12, prepared using (i) an internal batch mixer, (ii) a laboratory scale corotating twin screw extruder, and (iii) an industrial scale twin screw extruder. The average fiber lengths and fiber length distributions were measured for various compounding conditions (screw or rotor speed, mixing time, feed rate). Experimental results have shown that fiber breakage depends on both screw speed and mixing time, the later being controlled, in an extruder, by the feed rate. For a given compounding system (batch mixer or twin screw extruder), the energy input (specific mechanical energy, SME) during the compounding process is found to be a reliable parameter, which governs fiber length (average, minimal, and maximal) evolution. Experimental data are correctly described with a model defining change in fiber length as a function of SME. POLYM. COMPOS., 2011. © 2011 Society of Plastics Engineers     

Gas Hold‐up and Liquid Circulation Velocity in Gas‐Liquid‐Solid Airlift Reactors

Simple empirical correlations for gas hold‐up and liquid circulation velocity in two‐ and three‐phase airlift reactors are presented in this paper and their applicability has been demonstrated. The empirical correlations are good alternatives to the semi‐theoretical drift‐flux approach to predictions of gas hold‐ups and liquid circulation velocities in airlift reactors.     

Analysis of flow and mixing in screw elements of corotating twin‐screw extruders via SPH

Due to its meshless nature, the smoothed particle hydrodynamics method (SPH) provides high potential for the simulation of free‐surface flows and mixing in complex geometries. We used SPH to analyze the flow inside five typical screw elements of corotating twin‐screw extruders, two conveying elements, two kneading elements and a mixing element. Our results show conveying capabilities, pressure generation and power input for various operation states, completely and partially filled. We conducted a detailed mixing analysis based on tracer particles, which yielded the time evolution of the intensity of segregation for different tracers. From that, we determined exponential mixing rates, which describe the relative decrease of the intensity of segregation per screw revolution and characterize the mixing performance in different operation states. This provides valuable input information for simplified models of extruders, which are relevant to industrial applications and can significantly contribute to the efficient design, optimization and scale‐up of extruders. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2451–2463, 2017     

Modeling heterogeneous downward dense gas‐particle flows

A novel approach is proposed to model heterogeneous downward dense gas‐particle flows. The homogeneous behavior of the flow is described by the mass and momentum transport equations of the gas and particulate phases solved using a mono‐dimension finite volume method on staggered grids. The heterogeneous features of the flow are predicted simultaneously using the bubble‐emulsion formalism. The gas compressibility is taken into consideration. The model is supplemented with a new correlation to account for the wall‐particle frictional effects. The predictions are compared with the vertical profiles of pressure and the amount of gas that flows up and down two standpipes and a cyclone dipleg of an industrial fluid catalytic cracking unit and of a cold small‐scale circulating fluidized bed. The trends are well predicted. The model gives further information and is thus an innovative starting point for downward dense gas‐particle flow hydrodynamics investigation. © 2009 American Institute of Chemical Engineers AIChE J, 2010     

Euler–Lagrange modeling of a gas–liquid stirred reactor with consideration of bubble breakage and coalescence

Simulations of a gas–liquid stirred reactor including bubble breakage and coalescence were performed. The filtered conservation equations for the liquid phase were discretized using a lattice‐Boltzmann scheme. A Lagrangian approach with a bubble parcel concept was used for the dispersed gas phase. Bubble breakage and coalescence were modeled as stochastic events. Additional assumptions for bubble breakup modeling in an Euler–Lagrange framework were proposed. The action of the reactor components on the liquid flow field was described using an immersed boundary condition. The predicted number‐based mean diameter and long‐term averaged liquid velocity components agree qualitatively and quantitatively well with experimental data for a laboratory‐scale gas–liquid stirred reactor with dilute dispersion. Effects of the presence of bubbles, as well as the increase in the gas flow rate, on the hydrodynamics were numerically studied. The modeling technique offers an alternative engineering tool to gain detailed insights into complex industrial‐scale gas–liquid stirred reactors. © 2011 American Institute of Chemical Engineers AIChE J, 2012