Improved tools for bubble column reactor design and scale-up☆

Abstract This paper presents an extensive review of the kinetics, hydrodynamics, mass transfer, heat transfer and mathematical as well as computational fluid dynamics (CFD) modeling of Low-Temperature Tropsch Synthesis (LTFT) synthesis in Slurry Bubble Column Reactors (SBCRs), with the aim of identifying potential research and development areas in this particular field. The kinetic expressions developed for F-T synthesis over iron and cobalt catalysts along with the water gas shift (WGS) reactions are summarized and compared. The experimental data and empirical correlations to predict the hydrodynamics (gas holdup, Sauter mean bubble diameter, and bubble rise velocity), mass transfer coefficients and heat transfer coefficients are presented. The effects of various operating variables, including pressure, temperature, gas velocity, catalyst concentration, reactor geometry, and reactor internals on the hydrodynamic and transport parameters as well as the performance of SBCRs are discussed. Additionally, modeling efforts of SBCRs, using axial dispersion models (ADM), multiple cell recirculation models (MCCM) and computational fluid dynamics (CFD), are addressed. This review revealed the following: (1) Numerous F-T and WGS kinetic rate expressions are available for cobalt and iron catalysts and one must be careful in selecting the appropriate expressions for LTFT. Iron catalyst suffers from severe attrition and subsequent deactivation in SBCRs and accordingly building a costly catalyst manufacturing facility onsite is required to maintain a steady operation of the F-T reactor; (2) Experimental data on the hydrodynamic and transport parameters at high pressures and temperatures, typical to those of actual F-T synthesis, remain scanty when compared with the plethora of studies conducted using air–water systems in small reactors at ambient conditions; (3) Several empirical correlations for predicting the hydrodynamic and mass as well heat transfer parameters are available and one should select those which consider the reactor diameter, gas mixtures and the potential foamability of the F-T liquids; (4) The effect of cooling internals configuration and sparger design on the hydrodynamic and transport parameters, local turbulence, mixing and catalyst attrition are yet to be seriously addressed; (5) The impact of operating variables on the hydrodynamic and transport parameters as well as the overall performance of the SBCRs should be investigated using actual F-T fluid–solid systems under typical pressures and temperatures using a large-scale reactor (>0.15 m ID) in the presence of gas spargers and cooling internals; (6) Significant efforts are still required in order to advance CFD modeling of SBCRs, particularly those pertaining to the relevant closure models, such as drag, lift and turbulence. Also, cooling internals configuration and the design as well as orientation of gas spargers should be accounted for in the CFD modeling; and (7) Proper validations of the CFD formulations using actual systems for F-T SBCR are needed.

Fischer–Tropsch Synthesis in Slurry Bubble Column Reactors: Experimental Investigations and Modeling – A Review

https://repositorium.sdum.uminho.pt/bitstream/1822/1430/1/1999-11%5b1%5d.pdf

Hydrodynamic model for three-phase internal- and external-loop airlift reactors

Bubble columns have been the object of much attention these last 20 years; it has become a kind of benchmarking reactor for both advanced measuring techniques and for CFD. However, the classical approaches are still of interest, and improving these reactors is still a field of research. In the present article, first some reminders on classical approaches of bubble columns and airlift reactors are presented with recent applications, then the different aspects of CFD as applied to bubble columns are presented, then highlights on some features specific to non-Newtonian fluids are given, finally some attempts to improve bubble columns are presented.

Some Aspects of the Hydrodynamics of Bubble Columns

Gas suction and mass transfer in gas-liquid up-flow ejector loop reactors. Effect of nozzle and ejector geometry

A heterogeneous fluid dynamic model has been developed to describe the complex flow structure of two-phase flow in bubble columns. The equation of continuity and the momentum balances are the basis of the model. The coupling of the two phases is performed by a force of interaction which is deduced by a force balance around a single rising bubble. Multiphase flow mixing processes are taken into consideration by introducing the turbulent viscosities of the two phases involved. The model equations were implemented successfully by applying a tridiagonal matrix algorithm.

Hydrodynamics in bubble columns

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Hydrodynamics in bubble columns