Development of a Continuous Segmented Flow Tubular Reactor and the “Scale‐out” Concept – In Search of Perfect Powders

The synthesis of powders with controlled shape and narrow particle size distributions is still a major challenge for many industries. A continuous Segmented Flow Tubular Reactor (SFTR) has been developed to overcome homogeneity and scale‐up problems encountered when using batch reactors. Supersaturation is created by mixing the co‐reactants in a micromixer inducing precipitation; the suspension is then segmented into identical micro‐volumes by a non‐miscible fluid and sent through a tube. These micro‐volumes are more homogeneous when compared to large batch reactors leading to narrower size distributions, better particle morphology, polymorph selectivity and stoichiometry. All these features have been demonstrated on single tube SFTR for different chemical systems. To increase productivity for commercial application the SFTR is being “scaled‐out” by multiplying the number of tubes running in parallel instead of scaling‐up by increasing their size. The versatility of the multi‐tube unit will allow changes in type of precipitate with a minimum of new investment as new chemistry can be researched, developed and optimised in a single tube SFTR and then transferred to the multi‐tube unit for powder production.     

Gasification of Biogenic Solid Fuels

As a result of shrinking fossil fuels, biomass as a regenerative energy source gains importance. To realize biomass projects it is essential to investigate in convenient thermal procedures. On this evidence an analysis and evaluation of diverse gasification technologies with different boundary conditions and diverse biomasses are indispensable. Form and kind of the biomass as well as the type of the gasification plant cause different compositions of the product gas. The gasifiers show advantages and disadvantages concerning the biomass and the produced gas quality, depending on reactor type, kind of heat supply, gasification medium, and the pressure ratio in the reactor. As the ideal gasifier for different biomass is presently not available, it will be shown, which biomass is suitable for fixed bed or fluidized bed gasifiers.     

Investigation of an Ozone Membrane Contactor System

Ozone mass transfer rates were determined for nine expanded porous Teflon membranes that had different pore size, thickness, and pore volume, a nonporous Teflon membrane, and a PVDF membrane. The mass transfer coefficient was 7.6 ± 0.5 × 10^?5 m/s at Re of 2000 for all membranes tested even though pore sizes ranged from 0.07 to 6 μm and thickness from 0.076 to 0.25 mm. Mass transfer increased with liquid side Reynolds number. Therefore, it is likely that ozone mass transfer is liquid phase controlling and not membrane limited. For a hypothetical case of 4000 m³/d and 2 mg/L ozone transferred, plate and frame membrane and hollow fiber contactors are approximately one and two orders of magnitude smaller, respectively, than fine-bubble diffusers.     

Optimal Operating Conditions For Lab-Scale Ozonation Reactors

A method for the assessment of the optimal operating conditions for a mechanically stirred gas–liquid reactor is presented. The method exploits both fluid dynamic and chemical information. First, the behavior of the specific stirring power as a function of the stirrer speed allows singling out the dispersion region, in which the most efficient gas–liquid mass transfer is achieved. Inside this region, the analysis of experimental data obtained when considering a chemical system reacting at moderate Hatta numbers (i.e., Ha < about 2) allows determination of the rate constants and the fluid dynamic parameters (i.e., the mass transfer coefficient in the absence of chemical reaction and the characteristic diffusion time).     

Stimulating Biological Nitrification via Electrolytic Oxygenation

The feasibility of electric current prompted aerobic biodegradation of NH4+–N in an attached growth bioreactor system is demonstrated. Nitrification was induced at electric current densities of 1.25 and 2.5?mA/cm2 and with pure oxygen supplied at a rate equivalent to 1.25?mA/cm2 when the bioreactor was operated in batch mode at 6 days detention time. About 84% (27?mg/L)?NH4+–N loss was observed at the end of each detention period during all three experimental conditions, indicating that the electric current did not negatively impact the rate of nitrification. Nitrite accumulation was observed during the initial stages of nitrification experiments with 1.25?mA/cm2 current intensity, but nitrite did not accumulate during the other two sets of nitrification experiments. A mathematical model formulated to obtain the rates of biological reactions showed that rates of NH4+–N removal are similar for all aeration conditions. Abiotic experiments showed that NH4+–N was not removed electrolytically and via stripping, confirming that NH4+–N disappearance is due to biological activity.     

CFD simulation of fluidized bed reactors for polyolefin production – A review

This literature survey focuses on the application of computational fluid dynamics (CFD) in various aspects of the fluidized bed reactor. Although fluidized bed reactors are used in various industrial applications, this first-of-its-kind review highlights the use of CFD on polyolefin production. It is shown that CFD has been utilized for the following mechanisms of polymerization: governing of bubble formation, electrostatic charge effect, gas–solid flow behavior, particle distribution, solid–gas circulation pattern, bed expansion consequence, mixing and segregation, agglomeration and shear forces. Heat and mass transfer in the reactor modeling using CFD principles has also been taken under consideration. A number of softwares are available to interpret the data of the CFD simulation but only few softwares possess the analytical capability to interpret the complex flow behavior of fluidization. In this review, the popular softwares with their framework and application have been discussed. The advantages and feasibility of applying CFD to olefin polymerization in fluidized beds were deliberated and the prospect of future CFD applications was also discussed.     

Petri-net based modelling approach for ALFRED reactor operation and control system design

In this work, the Petri-net modelling approach applied to the control system design of the Advanced Lead Fast Reactor European Demonstrator (ALFRED) is presented, paying particular attention to the startup procedure. The reactor startup is the operational transient in which all the systems of the plant are brought from the cold shutdown condition to the full power mode, close to load-frequency control. In this phase, the several control actions to be taken need to be properly coordinated. To this end, the operational sequence which constitutes the reactor startup procedure has been described by adopting the Petri-nets approach, i.e., a useful formalism for the modelling and the analysis of Discrete Event Systems. Thanks to this quantitative representation, it is possible to easily derive the corresponding control scheme. In addition, the Petri-nets approach has been also exploited for the two-level control system architecture, namely a master system coordinates the operation of the plant by sending suitable signals to the slave system, in which feedback controllers are implemented. As a major outcome of this work, the procedure for the reactor startup and the transition to the full power mode has been simulated in order to assess the control system performance.     

Water Treatment Units Residence-Time Distributions as Probabilistic Functions

A probabilistic approach to obtain theoretical residence-time distribution (RTD) functions for series of reactors with possible stagnation, bypassing, and recycle is presented. It is shown that most known RTD functions can be obtained from probability arguments alone, thus avoiding abstract Laplace transform mathematical techniques and providing additional physical insight. Several new RTD models for reactors in series are derived, based exclusively on using the binomial probability distribution to describe the passage of a particle through the treatment train with bypassing and stagnation possible at each individual reactor. The proposed RTD models are validated with travel time computer simulation of a large number of particles through the series of reactors. A MSExcel based computer procedure was programmed to obtain the nonideal flow parameters by minimizing the squared sum of the differences between tracer test data and the derived unit’s RTD function. The least squares parameter estimation procedure was used to fit theoretical RTDs to tracer data collected from real water treatment units with different hydraulic behavior at two locations in Mexico.     

Combined Removal of Carbon and Nitrogen in an Integrated UASB-Jet Loop Reactor Bioreactor System

An innovative anaerobic–aerobic integrated bioreactor system consisting of an upflow anaerobic sludge blanket (UASB) and a jet loop reactor was developed to investigate the feasibility of combined removal of carbon and nitrogen for a low-strength wastewater at different hydraulic retention times (HRTs) and recycle ratios. Total chemical oxygen demand (COD) removal of the integrated system increased from 87 to 92%, at a combined system HRT of 44?h, when the recycle ratio was increased from 100 to 400%, respectively. Denitrification efficiency of the integrated system increased from 49 to 86%, at all HRTs, when the recycle ratio was increased from 100 to 400%. The integrated system, on average, achieved more than 78% of total nitrogen at all HRTs. Nitrogen content of the biogas produced from the UASB reactor increased with increase in recycle ratios while the methane content exhibited a reverse trend, irrespective of the HRTs. Sludge volume index of the UASB reactor increased from 15?to?42?mL/g total suspended solids at the end of the study. Specific methanogenic activity of the granular sludge decreased from 1.3 to 0.8 g CH4–COD/g volatile suspended solids per day at the end of the study. Nitrogen and COD mass balance of the integrated system indicated that a substantial amount of influent nitrogen and COD was lost in the effluent as dissolved form.     

Removal of Lead from Contaminated Water and Clay Soil Using a Biosurfactant

Lead removal from water and contaminated soils was investigated using biosurfactant, anionic, and nonionic surfactants in continuously stirred batch reactors. Lead-contaminated water up to 100?mg/L and clay soil up to 3,000?mg/kg were used in this investigation. The surfactant concentration up to 10 critical micelle concentration was used. The speciation of lead into the micelles was quantified and the lead removal efficiency depended on the level of contamination, surfactant type, and concentration. Of the surfactants used, biosurfactant (produced from used vegetable oil) had the best removal efficiency (75%) at a lead contamination of 100?mg/L in water at pH of over 12. The Fourier-transformed infrared spectroscopy study showed that the carboxyl group in the biosurfactant was effective in removing the lead from the solution. Langmuir and Freundlich relationships were used to represent the micelle partitioning of lead in the surfactant solutions. Desorption of lead from contaminated kaolinite clay was represented using linear isotherms. The biosurfactant solution had a higher micelle partitioning for the lead from contaminated water and desorbing the lead from the contaminated soil compared to the other chemical surfactants.