Bubble reactor design aspects

Scaling up of bubble columns is generally based on the requirement of keeping kiA constant. Since A is proportional to, this imphes keeping the superflcial gas velocity constant. Some design aspects of bubble reactors will be illustrated in an example following the section on stirred vessel reactors. 

Airlift loop reactor (ALR), basically a specially structured bubble column, has been widely used in chemical industry, biotechnology and environmental protection, due to its high efficiency in mixing, mass transfer, heat transfer etc [1]. In these processes, multiple reactions are commonly involved, in addition to their complicated aspects of mixing, mass transfer, and heat transfer. The interaction of all these obviously affects selectivity of the desired products [2]. It is, therefore, essential to develop efficient computational flow models to reveal more about such a complicated process and to facilitate design and scale up tasks of the reactor. However, in the past decades, most involved studies were usually carried out in air-water system and the assumed reactor constructions were oversimplified which kept itself far away from the real industrial conditions [3] [4]. 

The relatively low conversions of the gaseous reactant in many processes, like the chlorination of toluene above, pose problems for the process design of such operations. One approach for the chlorine-toluene process would be simply to pass the C12-HC1 mixture through a downstream section of plant to separate the unreacted chlorine which would then be recycled to the reactor. In an alternative design chlorine might be passed from the first reactor into a second reactor in series, and then if necessary into a third reactor, and so on, as shown in Fig. 4.7. However, the problem arises because a bubble column with a low aspect ratio or a singleimpeller agitated tank behaves essentially as a well-mixed reactor (aspect ratio is... 

An important aspect of the design of three phase bubble columns is the variation of catalyst distribution along the reactor height, and its effect on reactor performance. Many factors influence the degree of catalyst distribution, including gas velocity, liquid velocity, solid particle size, phase densities, slurry viscosity, and, to a lesser extent, column diameter, solid shape and chemical affinity between the solid and liquid phases. 

To simulate the effects of reaction kinetics, mass transfer, and flow pattern on homogeneously catalyzed gas-liquid reactions, a bubble column model is described [29, 30], Numerical solutions for the description of mass transfer accompanied by single or parallel reversible chemical reactions are known [31]. Engineering aspects of dispersion, mass transfer, and chemical reaction in multiphase contactors [32], and detailed analyses of the reaction kinetics of some new homogeneously catalyzed reactions have been recently presented, for instance, for polybutadiene functionalization by hydroformylation in the liquid phase [33], car-bonylation of 1,4-butanediol diacetate [34] and hydrogenation of cw-1,4-polybutadiene and acrylonitrile-butadiene copolymers, respectively [10], which can be used to develop design equations for different reactors. 

Although considerable advances have been made both in understanding the basic aspects of slurry bubble column reactors (SBCR) and in developing rational design procedures, computational fluid dynamics (CFD) - assisted design methodology for reactor optimization is sparse. 

Part A gives general guidelines for the design of large commercial fluidized bed reactors with respect to the following aspects (1) solids properties and their effect on the quality of fluidization (2) bubble size control through small solid particle size or baffles (3) particle recovery by means of cyclones (4) heat transfer tubes (5) solids circulation systems (6) instrumentation, corrosion and erosion, mathematical models, pilot plants and scale-up techniques. 

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