Interfacial mass transfer area

In this chapter, we study various correlations for gas-liquid mass transfer, interfacial area, bubble size, gas hold-up, agitation power consumption, and volumetric mass-transfer coefficient, which are vital tools for the design and operation of fermenter systems. Criteria for the scale-up and shear sensitive mixing are also presented. First of all, let s review basic mass-transfer concepts important in understanding gas-liquid mass transfer in a fermentation system. 

The term Z-aws represents the ratio of the actively wetted external catalyst area per unit volume of reactor,while ag represents the gas-to-liquid mass transfer interfacial area per unit volume of reactor. 

Correlations are next reported for gas-liquid mass transfer, interfacial area, bubble size, gas hold-up, agitation power consumption, and volumetric mass-transfer coefficients, which are vital tools for the design and operation of fermenter systems. 

Flow regimes, pressure drop, phase holdup, liquid distribution, mixing, residence time distribution, heat and mass transfer, interfacial areas... 

It should be noted that PBRs operate differently than other gas-Uquid reactors covered so far. In the other reactor designs, the gas phase is dispersed in the liquid phase such that bubbles are formed from which the gas phase is transferred to the liquid. The surface area through which the transfer occurs is the interfacial area of the bubbles. In PBRs, general operation yields droplets or liquid films immersed in the gas phase, which causes the main transfer surface to be the droplet-gas or film-gas interface. In order to increase the mass transfer interiacial area, smaUer droplets or wavier films have to be produced. This process is often turbulent and may result in liquid breakup and coalescence, which may be destractive to some microorganisms (specifically those that are shear sensitive). 

Other correlations based partially on theoretical considerations but made to fit existing data also exist (71—75). A number of researchers have also attempted to separate from a by measuring the latter, sometimes in terms of the wetted area (76—78). Finally, a number of correlations for the mass transfer coefficient itself exist. These ate based on a mote fundamental theory of mass transfer in packed columns (79—82). Although certain predictions were verified by experimental evidence, these models often cannot serve as design basis because the equations contain the interfacial area as an independent variable. 

The rate of mass transfer (qv) depends on the interfacial contact area and on the rate of mass transfer per unit interfacial area, ie, the mass flux. The mass flux very close to the Hquid—Hquid interface is determined by molecular diffusion in accordance with Pick s first law ... 

Interfacial Contact Area and Approach to Equilibrium. Experimental extraction cells such as the original Lewis stirred cell (52) are often operated with a flat Hquid—Hquid interface the area of which can easily be measured. In the single-drop apparatus, a regular sequence of drops of known diameter is released through the continuous phase (42). These units are useful for the direct calculation of the mass flux N and hence the mass-transfer coefficient for a given system. 

In industrial equipment, however, it is usually necessary to create a dispersion of drops in order to achieve a large specific interfacial area, a, defined as the interfacial contact area per unit volume of two-phase dispersion. Thus the mass-transfer rate obtainable per unit volume is given as... 

The pulsed-plate column is typically fitted with hori2ontal perforated plates or sieve plates which occupy the entire cross section of the column. The total free area of the plate is about 20—25%. The columns ate generally operated at frequencies of 1.5 to 4 H2 with ampHtudes 0.63 to 2.5 cm. The energy dissipated by the pulsations increases both the turbulence and the interfacial areas and greatly improves the mass-transfer efficiency compared to that of an unpulsed column. Pulsed-plate columns in diameters of up to 1.0 m or mote ate widely used in the nuclear industry (139,140). 

R is rate of reaction per unit area, a is interfacial area per unit volume, S is solubiHty of solute in continuous phase, D is diffusivity of solute, k is rate constant, kj is mass-transfer coefficient, is concentration of reactive species, and Z is stoichiometric coefficient. When Dk is considerably greater (10 times) than Ra = aS Dk. 

Static mixing of gas—Hquid systems can provide good interphase contacting for mass transfer and heat transfer. Specific interfacial area for the SMV (Koch/Sulzer) mixer is related to gas velocity and gas holdup ( ) by the following ... 

Manufacture and Processing. Mononitrotoluenes are produced by the nitration of toluene in a manner similar to that described for nitrobenzene. The presence of the methyl group on the aromatic ring faciUtates the nitration of toluene, as compared to that of benzene, and increases the ease of oxidation which results in undesirable by-products. Thus the nitration of toluene generally is carried out at lower temperatures than the nitration of benzene to minimize oxidative side reactions. Because toluene nitrates at a faster rate than benzene, the milder conditions also reduce the formation of dinitrotoluenes. Toluene is less soluble than benzene in the acid phase, thus vigorous agitation of the reaction mixture is necessary to maximize the interfacial area of the two phases and the mass transfer of the reactants. The rate of a typical industrial nitration can be modeled in terms of a fast reaction taking place in a zone in the aqueous phase adjacent to the interface where the reaction is diffusion controlled. 

Under equiUbrium or near-equiUbrium conditions, the distribution of volatile species between gas and water phases can be described in terms of Henry s law. The rate of transfer of a compound across the water-gas phase boundary can be characterized by a mass-transfer coefficient and the activity gradient at the air—water interface. In addition, these substance-specific coefficients depend on the turbulence, interfacial area, and other conditions of the aquatic systems. They may be related to the exchange constant of oxygen as a reference substance for a system-independent parameter reaeration coefficients are often known for individual rivers and lakes. 

Wa Interpbase mass-transfer rate of solute A per interfacial area with respect to fixed coordinates kmoP(s-m ) (lbmol)/(h-fF)... 

The important point to note here is that the gas-phase mass-transfer coefficient fcc depends principally upon the transport properties of the fluid (Nsc) 3nd the hydrodynamics of the particular system involved (Nrc). It also is important to recognize that specific mass-transfer correlations can be derived only in conjunction with the investigator s particular assumptions concerning the numerical values of the effective interfacial area a of the packing. 

With complicated geometries, the product of the interfacial area per volume and the mass-transfer coefficient is required. Correlations of kop or of HTU are more accurate than individual correlations of k and since the measurements are simpler to determine the produc t kop or HTU. 

To determine the mass-transfer rate, one needs the interfacial area in addition to the mass-transfer coefficient. For the simpler geometries, determining the interfacial area is straightforward. For packed beds of particles a, the interfacial area per volume can be estimated as shown in Table 5-27-A. For packed beds in distillation, absorption, and so on in Table 5-28, the interfacial area per volume is included with the mass-transfer coefficient in the correlations for HTU. For agitated liquid-liquid systems, the interfacial area can be estimated... 

Effective Interfacial Mass-Transfer Area a In a packed tower of constant cross-sectional area S the differential change in solute flow per unit time is given by... 

In developing correlations for the mass-transfer coefficients Icq and /cl, the various authors have assumed different but internally compatible correlations for the effective interfacial area a. It therefore would be inappropriate to mix the correlations of different authors unless it has been demonstrated that there is a valid area of overlap between them. 

Volumetric Mass-Transfer Coefficients and Kia Experimental determinations of the individual mass-transfer coefficients /cg and /cl and of the effective interfacial area a involve the use of extremely difficult techniques, and therefore such data are not plentiful. More often, column experimental data are reported in terms of overall volumetric coefficients, which normally are defined as follows ... 

Experimental values of Hqg -nd Hql for a number of distillation systems of commercial interest are also readily available. Extrapolation of the data or the correlations to conditions that differ significantly from those used for the original experiments is risky. For example, pressure has a major effect on vapor density and thus can affect the hydrodynamics significantly. Changes in flow patterns affeci both mass-transfer coefficients and interfacial area. 

Designed to obtain such fundamental data as chemical rates free of mass transfer resistances or other complications. Some of the heterogeneous reactors of Fig. 23-29, for instance, employ known interfacial areas, thus avoiding one uncertainty. 

Flow Reactors Fast reactions and those in the gas phase are generally done in tubular flow reaclors, just as they are often done on the commercial scale. Some heterogeneous reactors are shown in Fig. 23-29 the item in Fig. 23-29g is suited to liquid/liquid as well as gas/liquid. Stirred tanks, bubble and packed towers, and other commercial types are also used. The operadon of such units can sometimes be predicted from independent data of chemical and mass transfer rates, correlations of interfacial areas, droplet sizes, and other data. 

Equations (13-111) to (13-114), (13-118) and (13-119), contain terms, Njj, for rates of mass transfer of components from the vapor phase to the liquid phase (rates are negative if transfer is from the liquid phase to the vapor phase). These rates are estimated from diffusive and bulk-flow contributions, where the former are based on interfacial area, average mole-fraction driving forces, and mass-... 

According to this method, it is not necessaiy to investigate the kinetics of the chemical reactions in detail, nor is it necessary to determine the solubihties or the diffusivities of the various reactants in their unreacted forms. To use the method for scaling up, it is necessaiy independently to obtain data on the values of the interfacial area per unit volume a and the physical mass-transfer coefficient /c for the commercial packed tower. Once these data have been measured and tabulated, they can be used directly for scahng up the experimental laboratory data for any new chemic ly reac ting system. 

There are a number of different types of experimental laboratory units that could be used to develop design data for chemically reacting systems. Charpentier [ACS Symp. Sen, 72, 223-261 (1978)] has summarized the state of the art with respect to methods of scaUng up lab-oratoiy data and tabulated typical values of the mass-transfer coefficients, interfacial areas, and contact times to be found in various commercial gas absorbers as well as in currently available laboratoiy units. 

It would be desirable to reinterpret existing data for commercial tower packings to extract the individual values of the interfacial area a and the mass-transfer coefficients fcc and /c in order to facilitate a more general usage of methods for scaling up from laboratory experiments. Some progress in this direction has afready been made, as discussed later in this section. In the absence of such data, it is necessary to operate a pilot plant or a commercial absorber to obtain kc, /c , and a as described by Ouwerkerk (op. cit.). 

Principles of Rigorous Absorber Design Danckwerts and Alper [Trans. Tn.st. Chem. Eng., 53, 34 (1975)] have shown that when adequate data are available for the Idnetic-reaciion-rate coefficients, the mass-transfer coefficients fcc and /c , the effective interfacial area per unit volume a, the physical solubility or Henry s-law constants, and the effective diffusivities of the various reactants, then the design of a packed tower can be calculated from first principles with considerable precision. 

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