Partial wetting/mass transfer/catalyst

Partial Wetting/Mass Transfer/Catalyst Effectiveness Scaleup Model... 

Failing to identify the limiting reactant can lead to failure in the scale-up of trickle-bed reactors (Dudukovic, 1999). Gas-limited reactions occur when the gaseous reactant is slightly soluble in the liquid and at moderate operating pressures. For liquid-limited reactions, concurrent upflow is preferred (packed bubble columns) as it provides for complete catalyst wetting and thus enhances the mass transfer from the liquid phase to the catalyst. On the other hand, for gas reactions, concurrent downflow operation (trickle-bed reactors), especially at partially wetted conditions, is preferred as it facilitates the mass transfer from the gas phase to the catalyst. The differences between upflow and downflow conditions disappear by the addition of fines (see Section 3.7.3, Wetting efficiency in trickle-bed reactors). 

Possibility of operating partially or wholly in the vapour phase by varying the liquid flowrate according to catalyst wetting, heat of vaporization, and mass-transfer resistances in the liquid phase. 

Catalyst particles are small, so less chance of diffusional resistance to mass transfer. (2) Better control of temperature (because of better heat transfer efficiency and high heat capacity of slurries), attractive for exothermic reactions. (3) No need to shut down for catalyst replacement or reactivation. (4) Partial wetting and need to maintain a coating film of liquid (as needed in the trickle bed) are not issues. (5) The space time yield is usually better in slurry reactors (under comparable conditions). 

Most common in practice is a trickling flow that occurs at relatively low gas and liquid flow rates. Under these conditions in trickle-bed reactors (TBRs) complete liquid films around the particles would break up into partial films, rivulets and droplets and a so-called partial wetting trickling regime exist. It is easier for hydrogen to enter the no wetted or very thin wetted part of partially wetted catalyst pellets because the mass-transfer resistance between a gas and the particle sur-... 

The developed dynamic reactor model for the simulation studies of the unsteady-state-operated trickle-flow reactor is based on an extended axial dispersion model to predict the overall reactor performance incorporating partial wetting. This heterogeneous model consists of unsteady-state mass and enthalpy balances of the reaction components within the gas, liquid and catalyst phase. The individual mass-transfer steps at a partially wetted catalyst particle are shown in Fig. 4.5. 

A multiphase reactor design, very similar to the trickle-bed reactor, is the tubular multiphase hollow membrane wall reactor sketched in Eigure 13.2h. In a regular trickle-bed reactor, the liquid flows over a partially wetted pellet as a thin film and supplies the liquid phase reactant to the catalyst pores. This action, however, has the effect of hindering pore access to the gas, thus lowering the reaction rate. On the other hand, in the multiphase membrane reactor, the liquid-filled membrane is directly accessible to the gas flowing in the inside tube. Thus, mass transfer in this reactor is considerably more efficient than in the conventional trickle-bed reactor. 

Interphase Mass Transfer. There are a number of interphase mass transfer steps that must occur in a trickle flow reactor. The mass transfer resistances can be considered as occurring at the more or less stagnant fluid layer interfaces, i.e., on the gas and/or the liquid side of the gas/llquld Interface and on the liquid side of the liquid/solid Interface. The mass transfer correlations (8) indicate that the gas/llquld Interface and the liquid/solid interface mass transfer resistances decrease with higher liquid velocity and smaller particle size. Thus, in the PDU, the use of small inert particles partially offsets the adverse effect of low velocity. These correlations indicate that for this system, external mass transfer limitations are more likely to occur in the PDU than in the commercial reactor because of the lower liquid velocity, but that probably there is no limitation in either. If a mass transfer limitation were present, it would limit conversion in a way similar to that shown for axial dispersion and incomplete catalyst wetting illustrated in Figure 1. Due to the uncertainty in the correlations and in the physical properties of these systems, particularly the molecular diffuslvities, it is of interest to examine if external mass transfer is influencing the PDU results. 

Trickle-bed reactors, wherein gas and liquid reactants are contacted in a co-current down flow mode in the presence of heterogeneous catalysts, are used in a large number of industrial chemical processes. Being a multiphase catalytic reactor with complex hydrodynamics and mass transfer characteristics, the development of a generalized model for predicting the performance of such reactors is still a difficult task. However, due to its direct relevance to industrial-scale processes, several important aspects with respect to the influence of external and intraparticle mass transfer effects, partial wetting of catalyst particles and heat effects have been studied previously (Satterfield and Way (1972) Hanika et. al., (1975,1977,1981) Herskowitz and Mosseri (1983)). The previous work has mainly addressed the question of catalyst effectiveness under isothermal conditions and for simple kinetics. It is well known that most of the industrially important reactions represent complex reaction kinetics and very often multistep reactions. Very few attempts have been made on experimental verification of trickle-bed reactor models for multistep catalytic reactions in the previous work. 

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