Flow trickling

As with the falling film reactor, the rate of mass transfer to the catalyst goes as R, while the size of the reactor goes as R, so this reactor becomes very inefficient except for very small-diameter tubes. However, we can overcome this problem, not by using many small tubes in parallel, but by allowing the gas and liquid to flow (trickle) over porous catalyst pellets in a trickle bed reactor rather than down a vertical wall, as in the catalytic wall reactor. 

Fig. 4.17. Flow regimes in three-phase fixed-bed reactors, (a) Gas and liquid in co-current downwards flow (trickle-bed operation). (b) Gas and liquid in co-current upwards flow (liquid floods bed), (c) Gas and liquid in countercurrent flow (not often used for catalytic reactors)...

In concurrent downward-flow trickle beds of 1 meter in height and with diameters of respectively 5, 10 and 20 cm, filled with different types of packing material, gas-continuous as well as pulsing flow was realized. Residence time distribution measurements gave information about the liquid holdup, its two composing parts the dynamic and stagnant holdup and the mass transfer rate between the two. 

Ng, K.M. "A Model for Flow Regime Transitions in Cocurrent Down-Flow Trickle-Bed Reactors" submitted to Ind. Eng. Chem. Fundam. 1983. 

When (a) there are no external mass-transfer resistances (such as gas-liquid, liquid solid, etc.), (b) catalysts are all effectively wetted, (< ) there is no radial or axial dispersion in the liquid phase, (d) a gaseous reactant takes part in the reaction and its concentration in the liquid film is uniform and in excess, (e) reaction occurs only at the liquid-solid interface, (/) no condensation or vaporization of the reactant occurs, and (g) the heat effects are negligible, i.e., there is an isothermal operation, then a differential balance on such an ideal plug-flow trickle-bed reactor would give... 

De Waal and Van Mameren14 studied the RTD in the gas phase for an air-water system in a 30.48-cm-diameter, 3.05-m-tall countercurrent flow trickle-... 

In a trickle bed reactor the gas and liquid flow (trickle) concurrently downward over a packed bed of catalyst particles. Industrial trickle beds are typically 3 to 6 m deep and up to 3 m in diameter and are filled with catalyst particles ranging irom to in. in diameter. The pores of the catalyst are filled with liquid. In petroleum refining, pressures of 34 to 100 atm and temperatures of 350 to 425°C are not uncommon. A pilot-plant trickle bed reactor might be about 1 m deep and 4 cm in diameter. Trickle beds are used in such processes as the hydrodesulfurization of heavy oil stocks, the hydrotreating of lubricating oils, and reactions such as the production of butynediol from acetylene and aqueous formaldehyde over a copper acetylide catalyst. It is on this latter type of reaction,... 

Despite the experience with batch reactors it may be worthwhile to operate continuous reactors also for fine chemicals. Continuously operated reactors only demand for one start-up and one shut-down during the production series for one product. This increases the operating time efficiency and prevents the deactivation of dry catalysts this implies that the reactor volume can be much smaller than for batch reactors. As to the reactor type for three phase systems an agitated slurry tank reactor [5,6] is not advisable, because of the good mixing characteristics. Specially for consecutive reaction systems the yields to desired products and selectivities will be considerably lower than in plug flow type reactor. The cocurrent down flow trickle flow reactor... 

Fig. 30. Contacting patterns and contactor types for gas-liquid-solid reactors, (a) Co-current downflow trickle bed. (b) Countercurrent flow trickle bed. (c) Co-current downflow of gas, liquid, and catalyst, (d) Downflow of catalyst and co-current upflow of gas and liquid, (e) Multi-tubular trickle bed with co-current flow of gas and liquid down tubes with catalyst packed inside them coolant on shell side, (f) Multi-tubular trickle bed with downflow of gas and liquid coolant inside the tubes, (g) Three-phase fluidized bed of solids with solids-free freeboard, (h) Three-phase slurry reactor with no solids-free freeboard, (i) Three-phase fluidized beds with horizontally disposed internals to achieve staging, (j) Three-phase slurry reactor with horizontally disposed internals to achieve staging, (k) Three-phase fluidized bed in which cooling tubes have been inserted coolant inside the tubes. (1) Three-phase slurry... 

For reactions at a relatively low reaction rate which are, however, highly exothermic a pulsed flow trickle bed shows good features and induced pulsed flow is then a wanted design criterion. 

Ng KM. A model for flow regime transitions in cocurrent down-flow trickle-bed reactors. AIChE J. 1986 32 115. 

Zimmerman SP, Ng KM. Liquid distribution in trickling flow trickle-bed reactors. Chem. Eng. Sci. 1986 41(4) 861-866. 

The flow conditions in a trickle bed reactor are illustrated in Figure 6.9. At low gas and liquid flows, a trickle flow dominates if the flow rates are higher, a pulsed flow develops in the reactor. At low gas and high liquid flows, the liquid phase is continuous and gas bubbles flow through the liquid phase. At high gas velocities, the gas phase is continuous and the liquid droplets are dispersed in the gas flow (spray flow). Trickle bed reactors are usually... 

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