Cocurrent

Gas-liquid mixtures are sometimes reacted in packed beds. The gas and the liquid usually flow cocurrently. Such trickle-bed reactors have the advantage that residence times of the liquid are shorter than in countercurrent operation. This can be useful in avoiding unwanted side reactions. 

Fixed-bed reactors in the form of gas absorption equipment are used commonly for noncatalytic gas-liquid reactions. Here the packed bed serves only to give good contact between the gas and liquid. Both cocurrent and countercurrent operations are used. Countercurrent operation gives the highest reaction rates. Cocurrent operation is preferred if a short liquid residence time is required. 

Tunnel dryers are shown in Fig. 3.15a. Wet material on trays or a conveyor belt is passed through a tunnel, and drying takes place by hot air. The airflow can be countercurrent, cocurrent, or a mixture of both. This method is usually used when the product is not free flowing. 

FIgura 7.7 1-1 shells approach pure countercurrent flow, whereas 1-2 shells exhibit partial countercurrent and partial cocurrent flow. 

Steps. A pressure-swing cycle has at least three steps adsorption, blowdown, and repressurization. Although not always necessary, a purge step is normally used. In finely tuned processes, cocurrent depressurization and pressure-equalization steps are frequendy added. 

At the completion of adsorption, the less selectively adsorbed components have been recovered as product. However, a significant quantity of the weaMy adsorbed species are held up in the bed, especially in the void spaces. A cocurrent depressurization step reduces the bed pressure by allowing dow out of the bed cocurrendy to feed dow and thus reduces the amount of product retained in the voids (holdup), improving product recovery, and increases the concentration of the more strongly adsorbed components in the bed. The purity of the more selectively adsorbed species has been shown to depend strongly on the cocurrent depressurization step for some appHcations (66). A cocurrent depressurization step is optional because a countercurrent one always exists. Criteria have been developed to indicate when the use of both is justified (67). 

The repressurization step returns the adsorber to feed pressure and completes the steps of a PSA cycle. Pressurization is carried out with product and/or feed. Pressurizing with product is done countercurrent to adsorption so that purging of the product end continues indeed it may be merely a continuation of the purge step but with the bed exit valve closed. Pressurizing with feed cocurrent to adsorption in effect begins adsorption without producing any product. 

Fig. 15. Four-bed PSA system cycle sequence chart (64). EQ, equalization C D A, cocurrent depressurization C D T, countercurrent depressurization R, repressurization A, cocurrent flow T, countercurrent flow. Courtesy of American Institute of Chemical Engineers.

Steps. A purge-swing cycle usually has two steps, adsorption and purge. Sometimes, a cocurrent purge is added. After the adsorption step has been completed and the less selectively adsorbed components have been recovered, an appreciable amount of product is still stored in the bed. A purge cocurrent to feed can increase recovery by displacing the fluid held in the voids. 

Washing by successive dilution is used when the soHds are separated into a slurry, such as in filter thickeners. The soHds, thickened into a small amount of mother Hquor, are diluted into a wash Hquid and then separated again, diluted, separated, etc until clean of mother Hquor. The consumption of the wash Hquid can be reduced in countercurrent washing systems, sometimes referred to as countercurrent decantation. Cocurrent dilution washing, however, can be built into some dynamic filter-thickeners such as the Escher-Wyss filter. 

The I2 formed stays in solution, exerting a certain vapor pressure, and is extracted from the brine in a countercurrent air blow-out process. The extracted brine leaves the extraction tower and is discarded or reinjected into the wells to avoid sinking of the soil. The iodine-loaded air is then submitted to a cocurrent desorption process by means of an acidic iodide solution to which SO2 is added. By this solution the iodine is reduced to iodide by the following reaction ... 

The common types of dryers are rotary, hearth, flash (spray), and fluidized beds (10). Hot gases are used invariably to remove moisture. The gas flow can be either cocurrent or countercurrent to the flow of soHds, the former tends to be more efficient. In the hearths, the gas flow is countercurrent as the soHds are raked down from one hearth to the next below. Flash dryers are very rapid because the soHds are exposed only briefly to the hot gases. Fluidized-bed dryers, which use hot gases to suspend the soHds, are rapid and efficient, but require elaborate dust coHection systems. These are preferred when fine soHds are involved, and are used commonly for drying fine coal. Indirect-fired dryers are used when the soHds are heat sensitive or combustible. 

Fig. 13. Combined dryer—calciner processes for sodium tripolyphosphate (a) cocurrent rotary dryer—calciner (b) countercurrent rotary dryer—calciner and...

T. R. Melli, W. B. Kolb, J. M. deSantos, and L. E. Scriven, "Cocurrent Downflow in Packed Beds Microscale Roots of Macroscale Plow Regimes,"... 

After the SO converter has stabilized, the 6—7% SO gas stream can be further diluted with dry air, I, to provide the SO reaction gas at a prescribed concentration, ca 4 vol % for LAB sulfonation and ca 2.5% for alcohol ethoxylate sulfation. The molten sulfur is accurately measured and controlled by mass flow meters. The organic feedstock is also accurately controlled by mass flow meters and a variable speed-driven gear pump. The high velocity SO reaction gas and organic feedstock are introduced into the top of the sulfonation reactor,, in cocurrent downward flow where the reaction product and gas are separated in a cyclone separator, K, then pumped to a cooler, L, and circulated back into a quench cooling reservoir at the base of the reactor, unique to Chemithon concentric reactor systems. The gas stream from the cyclone separator, M, is sent to an electrostatic precipitator (ESP), N, which removes entrained acidic organics, and then sent to the packed tower, H, where SO2 and any SO traces are adsorbed in a dilute NaOH solution and finally vented, O. Even a 99% conversion of SO2 to SO contributes ca 500 ppm SO2 to the effluent gas. 

Convection heat transfer is dependent largely on the relative velocity between the warm gas and the drying surface. Interest in pulse combustion heat sources anticipates that high frequency reversals of gas flow direction relative to wet material in dispersed-particle dryers can maintain higher gas velocities around the particles for longer periods than possible ia simple cocurrent dryers. This technique is thus expected to enhance heat- and mass-transfer performance. This is apart from the concept that mechanical stresses iaduced ia material by rapid directional reversals of gas flow promote particle deagglomeration, dispersion, and Hquid stream breakup iato fine droplets. Commercial appHcations are needed to confirm the economic value of pulse combustion for drying. 

Gas flow in these rotary dryers may be cocurrent or countercurrent. Cocurrent operation is preferred for heat-sensitive materials because gas and product leave at the same temperature. Countercurrent operation allows a product temperature higher than the exit gas temperature and dryer efficiency may be as high as 70%. Some dryers have enlarged cylinder sections at the material exit end to increase material holdup, reduce gas velocity, and minimize dusting. Indirectly heated tubes are installed in some dryers for additional heating capacity. To prevent dust and vapor escape at the cylinder seals, most rotary dryers operate at a negative internal pressure of 50—100 Pa (0.5—1.0 cm of water). 

Fig. 14. Temperature profiles of gas and material ia direct-heat dryers (a) a countercurrent rotary dryer (b) a cocurrent rotary dryer and (c) a siagle-stage...

Fig. 17. Open-cycle, cocurrent, disk atomizer spray dryer.

Fig. 18. Product removal arrangements for cocurrent spray dryers (a) simple outlet (b) product separation ia an agglomeration chamber and (c) classifyiag...

For fully developed incompressible cocurrent upflow of gases and liquids in vertical pipes, a variety of flow pattern terminologies and descriptions have appeared in the hterature some of these have been summarized and compared by Govier, Radford, and Dunn Can. J. Chem. Eng., 35, 58-70 [1957]). One reasonable classification of patterns is illustrated in Fig. 6-28. 

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