Phase dispersion entrainment

Alternatively, the dispersed phase is chosen because, by definition, it will not contain droplets of the continuous phase. In this way the dispersed phase, after settling, will not entrain the continuous phase and entrainment losses from the settler will be reduced. 

Dispersed, Spray, or Mist Flow. Here, all of the liquid is entrained as fine droplets by the gas phase. Dispersed flow occurs for gas velocities greater than 200 ft/sec (60 m/sec). 

Pressurized wash liquid is sprayed in a jet scrubber, and dispersed into the slow flowing gas phase. The driving force is induced by the washing liquid the gas phase is entrained by the liquid jet or the droplet swarm (Fig. 3-23 a). 

The nonuniformity of drop dispersions can often be important in extraction. This nonuniformity can lead to axial variation of holdup in a column even though the flow rates and other conditions are held constant. For example, there is a tendency for the smallest drops to remain in a column longer than the larger ones, and thereby to accumulate and lead to a locali2ed increase in holdup. This phenomenon has been studied in reciprocating-plate columns (74). In the process of drop breakup, extremely small secondary drops are often formed (64). These drops, which may be only a few micrometers in diameter, can become entrained in the continuous phase when leaving the contactor. Entrainment can occur weU below the flooding point. 

Coalescence and Phase Separation. Coalescence between adjacent drops and between drops and contactor internals is important for two reasons. It usually plays a part, in combination with breakup, in determining the equiHbrium drop si2e in a dispersion, and it can therefore affect holdup and flooding in a countercurrent extraction column. Secondly, it is an essential step in the disengagement of the phases and the control of entrainment after extraction has been completed. 

Phenomena at Liquid Interfaces. The area of contact between two phases is called the interface three phases can have only aline of contact, and only a point of mutual contact is possible between four or more phases. Combinations of phases encountered in surfactant systems are L—G, L—L—G, L—S—G, L—S—S—G, L—L, L—L—L, L—S—S, L—L—S—S—G, L—S, L—L—S, and L—L—S—G, where G = gas, L = liquid, and S = solid. An example of an L—L—S—G system is an aqueous surfactant solution containing an emulsified oil, suspended soHd, and entrained air (see Emulsions Foams). This embodies several conditions common to practical surfactant systems. First, because the surface area of a phase iacreases as particle size decreases, the emulsion, suspension, and entrained gas each have large areas of contact with the surfactant solution. Next, because iaterfaces can only exist between two phases, analysis of phenomena ia the L—L—S—G system breaks down iato a series of analyses, ie, surfactant solution to the emulsion, soHd, and gas. It is also apparent that the surfactant must be stabilizing the system by preventing contact between the emulsified oil and dispersed soHd. FiaaHy, the dispersed phases are ia equiUbrium with each other through their common equiUbrium with the surfactant solution. 

Dilute This is a fully expanded condition in which the solids particles are so widely separated that they exert essentially no influence upon each other. Specifically, the solids phase is so fuUy dispersed in the gas that the den sity of the suspension is essentially that of the gas phase alone (Fig. 12-29). Commonly, this situation exists when the gas velocity at all points in the system exceeds the terminal setthng velocity of the solids and the particles can be lifted and continuously conveyed by the gas however, this is not always true. Gravity settling chambers such as prilling towers and countercurrent-flow spray diy-ers are two exceptions in which gas velocity is insufficient to entrain the sohds completely. 

Many experimental studies of entrainment have been made, but few of them have been made under actual distillation conditions. The studies are often questionable because they are hmited to the air-water system, and they do not use a realistic method for collecting and measuring the amount of entrainment. It is clear that the dominant variable affecting entrainment is gas velocity through the two-phase zone on the plate. Mechanisms of entrainment generation are discussed in the subsection Liquid-in-Gas Dispersions. ... 

Gases and liquids may be intentionally contacted as in absorption and distillation, or a mixture of phases may occur unintentionally as in vapor condensation from inadvertent cooling or liquid entrainment from a film. Regardless of the origin, it is usually desirable or necessary ultimately to separate gas-liquid dispersions. While separation will usually occur naturally, the rate is often economically intolerable and separation processes are employed to accelerate the step. 

Down spouts (or up spouts) are best set flush with the plate from which they lead, with no weir as in gas-hquid contact. The velocity of the continuous phase in the down spout V, which sets the down-spout cross section, should be set at a value lower than the terminal velocity of some arbitrarily small droplet of dispersed phase, say, 0.08 or 0.16 cm i M or Mfi in) in diameter otherwise, recirculation of entrained dispersed phase around a plate will result in flooding. The down spouts should extend beyond the accumulated layer of dispersed phase on the plate. 

The above two equations must be solved simultaneously and will require the solution of an equation of cubic form. These correlations are based on the gas phase being sparged into the mixing vessel. Gas dispersion from surface entrainment due to votexing, etc., is not included. The mixing power dissipation must be corrected... 

Most theoretical studies of heat or mass transfer in dispersions have been limited to studies of a single spherical bubble moving steadily under the influence of gravity in a clean system. It is clear, however, that swarms of suspended bubbles, usually entrained by turbulent eddies, have local relative velocities with respect to the continuous phase different from that derived for the case of a steady rise of a single bubble. This is mainly due to the fact that in an ensemble of bubbles the distributions of velocities, temperatures, and concentrations in the vicinity of one bubble are influenced by its neighbors. It is therefore logical to assume that in the case of dispersions the relative velocities and transfer rates depend on quantities characterizing an ensemble of bubbles. For the case of uniformly distributed bubbles, the dispersed-phase volume fraction O, particle-size distribution, and residence-time distribution are such quantities. 

For example, for equal volumes of gas and liquid ( =0.5), Eq. (266) predicts that the Stokes velocity (which is already very small for relatively fine dispersions) should be reduced further by a factor of 38 due to hindering effects of its neighbor bubbles in the ensemble. Hence in the domain of high values and relatively fine dispersions, one can assume that the particles are completely entrained by the continuous-phase eddies, resulting in a negligible convective transfer, although this does not preclude the existence of finite relative velocities between the eddies themselves. 

Solvent extraction carried out in conventional contactors like mixer-settlers and columns has certain limitations, including (a) controlling optimum dispersion and coalescence, (b) purifying both phases to ensure that stable emulsions are avoided (c) temperature control within a narrow band (d) high entrained solvent losses and related environmental and process economic effects and (e) large equipment dimensions and energy requirements when the density differential or selectivity is low. 

Check the continuous phase (hydrocarbon) droplets that could be entrained in the dispersed phase (water). 

Annular flow. In annular flow there is a continuous liquid in an annulus along the wall and a continuous gas/vapor phase in the core. The gas core may contain entrained droplets—dispersed mist—while the discontinuous gas phase appears as bubbles in the annulus. This flow pattern occurs at high void fractions and high flow velocities. A special case of annular flow is that where there is a gas/vapor film along the wall and a liquid core in the center. This type is called inverse annular flow and appears only in subcooled stable film boiling (see Sec. 3.4.6.3)... 

Chemically, the preparation of a "stable" foam or emulsion requires the use of a surfactant to aid in dispersion of the internal phase and prevent the collapse of the foam (or emulsion) into separate bulk phases. The selection of a surfactant is made on the basis of severity of conditions to be encountered, the gas to be entrained (N2, C02, LPG, CH, or air), the continuous phase liquid (water, alcohol, or oil), and half-life of foam stability desired. 

Entrained dispersed phase droplets, causing disperse-phase backmixing... 

In large-scale operation, the volumetrie flow of the phase to be dispersed is so large that it becomes neeessary to disperse that phase into the mixed phases. Otherwise blobs of the dispersed phase will act locally as the continuous phase, and the intended eontinuous phase will be dispersed in the blobs before the shear forees in the mixer break them up. This can lead to excessive entrainment losses. 

Figure 183. Drums with coalescers for assisting in the separation of small amounts of entrained liquid, (a) A liquid-liquid separating drum equipped with a coalescer for the removal of small amounts of dispersed phase. In water-hydrocarbon systems, the pot may be designed for 0.5 ft/sec (Facet Enterprises, Industrial Division), (b) An oil-water separator with corrugated plate coalescers (General Electric Co.).

---