CROSS-FLOW FILTRATION REACTORS

Figure 4.6. Cross-flow filtration reactor described by Livingston et a/.[14,15]...

Figure 6.14.7 Cross-flow filtration reactor for the separation of a size enlarged homogeneous catalyst from its reaction products. Adapted from Naireto/. (2002).

A continuous cross-flow filtration process has been utilized to investigate the effectiveness in the separation of nano sized (3-5 nm) iron-based catalyst particles from simulated Fischer-Tropsch (FT) catalyst/wax slurry in a pilot-scale slurry bubble column reactor (SBCR). A prototype stainless steel cross-flow filtration module (nominal pore opening of 0.1 pm) was used. A series of cross-flow filtration experiments were initiated to study the effect of mono-olefins and aliphatic alcohol on the filtration flux and membrane performance. 1-hexadecene and 1-dodecanol were doped into activated iron catalyst slurry (with Polywax 500 and 655 as simulated FT wax) to evaluate the effect of their presence on filtration performance. The 1-hexadecene concentrations were varied from 5 to 25 wt% and 1-dodecanol concentrations were varied from 6 to 17 wt% to simulate a range of FT reactor slurries reported in literature. The addition of 1-dodecanol was found to decrease the permeation rate, while the addition of 1-hexadecene was found to have an insignificant or no effect on the permeation rate. 

The pilot-scale SBCR unit with cross-flow filtration module is schematically represented in Figure 15.5. The SBCR has a 5.08 cm diameter and 2 m height with an effective reactor volume of 3.7 L. The synthesis gas passes continuously through the reactor and is distributed by a sparger near the bottom of the reactor vessel. The product gas and slurry exit at the top of the reactor and pass through an overhead gas/liquid separator, where the slurry is disengaged from the gas phase. Vapor products and unreacted syngas exit the gas/liquid separator and enter a warm trap (373 K) followed by a cold trap (273 K). A dry flow meter downstream of the cold trap measures the exit gas flow rate. 

Application of cross-flow filtration for the removal of FT wax products can be a useful technique to maintain a constant catalyst loading in an FTS reactor in continuous operation. Addition of 1-dodecanol (at a concentration of 6 wt%) was found to decrease the permeation rate of the cross-flow filter used for the separation of simulated FT wax and activated iron catalyst slurry. However, additional... 

More recently, the cross-flow filtration combustion configuration (Fig. 29), commonly used for powder production, was investigated (Dandekar et al., 1990). Within the reactor, a rectangular container holds the solid reactant powder, and the gaseous reactant is transported from the surroundings to the front not only by longitudinal flow from above, but also by countercurrent flow from ahead of the front. The assumptions used in the model were as follows ... 

In filtration unit operation, especially in microfiltration, one usually differentiates between dead-end filtration (with cake formation) and cross-flow filtration [25] (Fig. 5). The cross-flow filter can have different geometries (Fig. 6) phase membranes, tubular membranes, or pleated membranes, of which the tubular and pleated ones are already accepted as cross-flow geometries in reactor technology, as mentioned above. In filtration engineering the cross-flow term means that the filtrate flows perpendicularly to the suspension stream. Cross-flow may not be considered a sufficiently illustrative term here [25]. A better term would be parallel filtration, but the term cross-flow filtration has been accepted generally and may be difficult to change at present. 

In a general way, most of ceramic membrane modules operate in a cross-flow filtration mode [28] as shown in Figure 6.18. However, as discussed hereafter, a dead-end filtration mode may be used in some specific applications. Membrane modules constitute basic units from which all sorts of filtration plants can be designed not only for current liquid applications but also for gas and vapor separation, membrane reactors, and contactors, which represent the future applications of ceramic membranes. In liquid filtration, hydrodynamics in each module can be described as one incoming flow on the feed side gf, which results in two... 

Like enzymes, whole cells are sometimes immobilized by attachment to a surface or by entrapment within a support. One motivation for this is similar to the motivation for using biomass recycle in a continuous process. The cells are grown under optimal conditions for cell growth but are used at conditions optimized for production of a secondary metabolite. A hollow-liber reactor, similar to those used for cross-flow filtration, can be used to entrap the cells while allowing input of the substrate and removal of products. Attachment of the cells to a nonreactive material such as alumina allows a great variety of reactor types including packed beds, fluidized and spouted beds, and air-lift reactors. Packed beds with a biofilm on the packing are commonly used for wastewater treatment. A semicommercial process for beer used an air-lift reactor to achieve reaction times of one day compared to five to seven days for the normal batch process. Unfortunately, the beer suffered from a mismatched flavor profile that was attributed to mass transfer limitations. 

The dead-end setup is by far the easiest apparatus both in construction and use. Reactor and separation unit can be combined and only one pump is needed to pump in the feed. A cross-flow setup, on the other hand, needs a separation unit next to the actual reactor and an additional pump to provide a rapid circulation across the membrane. The major disadvantage of the dead-end filtration is the possibility of concentration polarization, which is defined as an accumulation of retained material on the feed side of the membrane. This effect causes non-optimal membrane performance since losses through membrane defects, which are of course always present, will be amplified by a high surface concentration. In extreme cases concentration polarization can also lead to precipitation of material and membrane fouling. A membrane installed in a cross-flow setup, preferably applied with a turbulent flow, will suffer much less from this... 

The three kinds of reactors already described in this section are all traditional cross-flow reactors with permeable plates or membranes. The electrochemical filter-press cell reactors used, e.g., for electrosynthesis, are equipped with cation-selective membranes to prevent mixing of the anolyte and the catholyte. These cell reactors are therefore good examples of the extended type of cross-flow reactors according to the definition transferred from the filtration field. The application of the electrochemical filter-press cell reactor technique... 

Lactic acid is an important additive and preservative agent in the chemical, cosmetics, pharmaceutical, and food industries. It is also used as the base for the production of biodegradable polymers like polylactates [4.12]. Its current worldwide production is estimated to be 40,000 tons per year. The results reported by Olmos-Dichara and coworkers [4.13] are typical of the results reported in many of the prior studies of this reaction system. They carried out a study comparing the performance of a batch reactor and a MBR for the production of lactic acid using L. cassei sp. rhamnosus as a biocatalyst. The MBR consists of the batch bioreactor coupled with a cross-flow mineral membrane filtration unit. MBR productivity was eight times that of the batch reactor, while the biomass concentration (77g f ) in the MBR was 19 times that found in the batch culture. 

In the context of PFC removal, the improvement of PAC filtration is of particular interest since sorption of PFC on GAC may be inefficient (see Sect. 2.1). The filtration effect for PAC can be achieved by its immobilization on an appropriate supporting material such as polystyrene balls (Haberer process) [66, 67] or porous polyurethane cylinders [68]. A relatively new process in drinking water and pool water treatment is the combination of PAC with membranes (MFAJF). A full-scale application of PAC/UF for water treatment is the CRIST AL process (Combined Reactors /ntegrating a Separation by membranes and Treatment by Adsorption in Liquid), which is applied in Slovenia, France, and Switzerland for drinking water treatment [20]. Thereby, PAC is added to the raw water prior to filtration via UF-membranes operated in cross-flow mode [20]. The PAC-membrane process can be... 

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