Multiphase flow reactors mixed

These methods hardly take spatial distributions of velocity field and chemical species or transient phenomena into account, although most chemical reactors are operated in the turbulent regime and/or a multiphase flow mode. As a result, yield and selectivity of commercial chemical reactors often deviate from the values at their laboratory or pilot-scale prototypes. Scale-up of many chemical reactors, in particular the multiphase types, is still surrounded by a fame of mystery indeed. Another problem relates to the occurrence of thermal runaways due to hot spots as a result of poor local mixing effects. 

The statistical description of multiphase flow is developed based on the Boltzmann theory of gases [37, 121, 93, 11, 94, 58, 61]. The fundamental variable is the particle distribution function with an appropriate choice of internal coordinates relevant for the particular problem in question. Most of the multiphase flow modeling work performed so far has focused on isothermal, non-reactive mono-disperse mixtures. However, in chemical reactor engineering the industrial interest lies in multiphase systems that include multiple particle t3q)es and reactive flow mixtures, with their associated effects of mixing, segregation and heat transfer. 

The tubular reactor is a vessel through which the flow is continuous. There are several configurations of tubular reactors suitable for multiphase work, e.g. for liquid-solid and gas-liquid-solid compositions. The flow patterns in these systems are complex. A fixed bed reactor is packed with catalyst, typically formed into pellets of some shape, and if the feed is single phase, a simple tubular plug-flow reactor may suffice (Figure 1.1). Mixed component feeds can be handled in modifications to this. 

The above discussion and examples illustrate that reactor scale models have not advanced much during the past decades and this hinders our ability to reduce risk in implementation of new more efficient catalytic technologies. To make progress, it is necessary to develop improved and more accurate descriptions of flow and mixing in typical multiphase reactors. Multiphase reactors frequendy encountered in practice (Fig. 1.10) such as risers, bubble columns, fluidized beds, packed beds, and stirred tanks are opaque so that not all flow visualization tools (Table 1.6) are suitable. 

This situation describes an emulsion reactor in which reacting drops (such as oil drops in water or water drops in oil) flow through the CSTR with stirring to make the residence time of each drop obey the CSTR equation. A spray tower (liquid drops in vapor) or bubble column or sparger (vapor bubbles in a continuous liquid phase) are also segregated-flow situations, but these are not always mixed. We wiU consider these and other multiphase reactors in Chapter 12. 

The mass balances [Eqs. (Al) and (A2)] assume plug-flow behavior for both the gas/vapor and liquid phases. However, real flow behavior is much more complex and constitutes a fundamental issue in multiphase reactor design. It has a strong influence on the reactor performance, for example, due to back-mixing of both phases, which is responsible for significant effects on the reaction rates and product selectivity. Possible development of stagnant zones results in secondary undesired reactions. To ensure an optimum model development for CD processes, experimental studies on the nonideal flow behavior in the catalytic packing MULTIPAK are performed (168). 

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