Industrial transport diffusivities

The individual membrane filtration processes are defined chiefly by pore size although there is some overlap. The smallest membrane pore size is used in reverse osmosis (0.0005—0.002 microns), followed by nanofiltration (0.001—0.01 microns), ultrafHtration (0.002—0.1 microns), and microfiltration (0.1—1.0 microns). Electro dialysis uses electric current to transport ionic species across a membrane. Micro- and ultrafHtration rely on pore size for material separation, reverse osmosis on pore size and diffusion, and electro dialysis on diffusion. Separation efficiency does not reach 100% for any of these membrane processes. For example, when used to desalinate—soften water for industrial processes, the concentrated salt stream (reject) from reverse osmosis can be 20% of the total flow. These concentrated, yet stiH dilute streams, may require additional treatment or special disposal methods. 

Generalized charts are appHcable to a wide range of industrially important chemicals. Properties for which charts are available include all thermodynamic properties, eg, enthalpy, entropy, Gibbs energy and PVT data, compressibiUty factors, Hquid densities, fugacity coefficients, surface tensions, diffusivities, transport properties, and rate constants for chemical reactions. Charts and tables of compressibiHty factors vs reduced pressure and reduced temperature have been produced. Data is available in both tabular and graphical form (61—72). 

These apparent restrictions in size and length of simulation time of the fully quantum-mechanical methods or molecular-dynamics methods with continuous degrees of freedom in real space are the basic reason why the direct simulation of lattice models of the Ising type or of solid-on-solid type is still the most popular technique to simulate crystal growth processes. Consequently, a substantial part of this article will deal with scientific problems on those time and length scales which are simultaneously accessible by the experimental STM methods on one hand and by Monte Carlo lattice simulations on the other hand. Even these methods, however, are too microscopic to incorporate the boundary conditions from the laboratory set-up into the models in a reahstic way. Therefore one uses phenomenological models of the phase-field or sharp-interface type, and finally even finite-element methods, to treat the diffusion transport and hydrodynamic convections which control a reahstic crystal growth process from the melt on an industrial scale. 

Stirred suspensions of droplets have proven to be a popular approach for studying the kinetics of liquid-liquid reactions [54-57]. The basic principle is that one liquid phase takes the form of droplets in the other phase when two immiscible liquids are dispersed. The droplet size can be controlled by changing the agitator speed. For droplets with a diameter < 0.15 cm the inside of the drop is essentially stagnant [54], so that mass transfer to the inside surface of the droplet occurs only by diffusion. In many cases, this technique can lack the necessary control over both the interfacial area and the transport step for determination of fundamental interfacial processes [3], but is still of some value as it reproduces conditions in industrial reactors. 

Ordinary or bulk diffusion is primarily responsible for molecular transport when the mean free path of a molecule is small compared with the diameter of the pore. At 1 atm the mean free path of typical gaseous species is of the order of 10 5 cm or 103 A. In pores larger than 1CT4 cm the mean free path is much smaller than the pore dimension, and collisions with other gas phase molecules will occur much more often than collisions with the pore walls. Under these circumstances the effective diffusivity will be independent of the pore diameter and, within a given catalyst pore, ordinary bulk diffusion coefficients may be used in Fick s first law to evaluate the rate of mass transfer and the concentration profile in the pore. In industrial practice there are three general classes of reaction conditions for which the bulk value of the diffusion coefficient is appropriate. For all catalysts these include liquid phase reactions... 

The previous models were developed for Brownian particles, i.e. particles that are smaller than about 1 pm. Since most times particles that are industrially codeposited are larger than this, Fransaer developed a model for the codeposition of non-Brownian particles [38, 50], This model is based on a trajectory analysis of particles, including convective mass transport, geometrical interception, and migration under specific forces, coupled to a surface immobilization reaction. The codeposition process was separated in two sub-processes the reduction of metal ions and the concurrent deposition of particles. The rate of metal deposition was obtained from the diffusion... 

When the two liquid phases are in relative motion, the mass transfer coefficients in either phase must be related to the dynamical properties of the liquids. The boundary layer thicknesses are related to the Reynolds number, and the diffusive transfer to the Schmidt number. Another complication is that such a boundary cannot in many circumstances be regarded as a simple planar interface, but eddies of material are transported to the interface from the bulk of each liquid which change the concentration profile normal to the interface. In the simple isothermal model there is no need to take account of this fact, but in most industrial circumstances the two liquids are not in an isothermal system, but in one in which there is a temperature gradient. The simple stationary mass transfer model must therefore be replaced by an eddy mass transfer which takes account of this surface replenishment. 

The activity calculated from (7) comprises both film and pore diffusion resistance, but also the positive effect of increased temperature of the catalyst particle due to the exothermic reaction. From the observed reaction rates and mass- and heat transfer coefficients, it is found that the effect of external transport restrictions on the reaction rate is less than 5% in both laboratory and industrial plants. Thus, Table 2 shows that smaller catalyst particles are more active due to less diffusion restriction in the porous particle. For the dilute S02 gas, this effect can be analyzed by an approximate model assuming 1st order reversible and isothermal reaction. In this case, the surface effectiveness factor is calculated from... 

All reactions involved in polymer chain growth are equilibrium reactions and consequently, their reverse reactions lead to chain degradation. The equilibrium constants are rather small and thus, the low-molecular-weight by-products have to be removed efficiently to shift the reaction to the product side. In industrial reactors, the overall esterification, as well as the polycondensation rate, is controlled by mass transport. Limitations of the latter arise mainly from the low solubility of TPA in EG, the diffusion of EG and water in the molten polymer and the mass transfer at the phase boundary between molten polymer and the gas phase. The importance of diffusion for the overall reaction rate has been demonstrated in experiments with thin polymer films [10]. 

In industrial PET synthesis, two or three phases are involved in every reaction step and mass transport within and between the phases plays a dominant role. The solubility of TPA in the complex mixture within the esterification reactor is critical. Esterification and melt-phase polycondensation take place in the liquid phase and volatile by-products have to be transferred to the gas phase. The effective removal of the volatile by-products from the reaction zone is essential to ensure high reaction rates and low concentrations of undesirable side products. This process includes diffusion of molecules through the bulk phase, as well as mass transfer through the liquid/gas interface. In solid-state polycondensation (SSP), the volatile by-products diffuse through the solid and traverse the solid/gas interface. The situation is further complicated by the co-existence of amorphous and crystalline phases within the solid particles. 

Both the mass-transfer approach as well as the diffusion approach are required to describe the influence of mass transport on the overall polycondensation rate in industrial reactors. For the modelling of continuous stirred tank reactors, the mass-transfer concept can be applied successfully. For the modelling of finishers used for polycondensation at medium to high melt viscosities, the diffusion approach is necessary to describe the mass transport of EG and water in the polymer film on the surface area of the stirrer. Those tube-type reactors, which operate close to plug-flow conditions, allow the mass-transfer model to be applied successfully to describe the mass transport of volatile compounds from the polymer bulk at the bottom of the reactor to the high-vacuum gas phase. 

The designs of some early electrochemical cells for industrial use were based on the beaker-type laboratory cell. One improvement to mass transport conditions was to rotate the working electrode, which decreases the thickness of the diffusion layer [20]. As small a gap as is practical between the working electrode and the counter... 

Due to the fact that industrial composites are made up of combinations of metals, polymers, and ceramics, the kinetic processes involved in the formation, transformation, and degradation of composites are often the same as those of the individual components. Most of the processes we have described to this point have involved condensed phases—liquids or solids—but there are two gas-phase processes, widely utilized for composite formation, that require some individualized attention. Chemical vapor deposition (CVD) and chemical vapor infiltration (CVI) involve the reaction of gas phase species with a solid substrate to form a heterogeneous, solid-phase composite. Because this discussion must necessarily involve some of the concepts of transport phenomena, namely diffusion, you may wish to refresh your memory from your transport course, or refer to the specific topics in Chapter 4 as they come up in the course of this description. 

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