Hydrodynamics of an Airlift Column for Aeration in Molten Sulfur

The airlift column is a promising technology for the removal of volatile gas from high-viscosity molten sulfur. However, a detailed analysis is lacking on the hydrodynamic properties inside the column, due to the difficulty in flow behavior detection in the opaque molten sulfur. In this work, we adopted the computational fluid dynamics simulation to understand the hydrodynamic behaviors in an airlift column for molten sulfur aeration. In addition, we analyzed the impacts of the superficial gas velocity (UGr) and column height on the hydrodynamic characteristics, such as gas holdup, average bubble diameter, and liquid circulation velocity (ULr) in the column. The simulation shows that at a constant column height of 15 m, an increase on gas holdup can be obtained with the increase of the superficial gas velocity, while the bubble diameter remains almost constant. Once the superficial gas velocity exceeded 0.333 m/s, the liquid circulation velocity increased slowly. With a variation on the column height from 5 to 25 m, a negligible change on gas holdup, but an obvious increase on liquid circulation velocity and bubble diameter is observed at the given superficial gas velocity of 0.0389 m/s. Furthermore, the simulation shows a similar trend, but with considerably more detailed information, on the relationship between the gas holdup and liquid circulation velocity when compared to the predictions from the Chisti correlation (1988) and an optimized correlation proposed in this work.

Modeling and Optimization of Gas-Solid Fluidization of Binary Mixtures using Box-Behnken Experimental Design

The influence of different factors on the fluidization of a binary mixture of red mud and aluminum was investigated. A new model was developed for predicting pressure drop through the solid bed using experimental data of other work. Statistical analysis based on response surface methodology has been used to develop correlations for bed pressure drop with three independent factors, minimum fluidization velocity (Umf), red mud to aluminum ratio (R/A), and static head (Hs). The design of experiments offers a best alternative to study the effect of factors and their response with the minimum number of experiments. The hydrodynamic characteristics of fluidization, bed pressure drop, superficial gas velocity (Umf), red mud to aluminum ratio (R/A), and initial static bed height (Hs) were modeled and optimized. ANOVA has been used to analyze the system parameters on bed pressure drop. A model of bed pressure drop was found to have a correlation coefficient of 0.98. The measured values of bed pressure drop from RSM were found to match the experimental values very well.

Gas-liquid flows through porous media in microgravity: Packed Bed Reactor Experiment-2

Experimental results on pressure drop and gas hold-up for gas-liquid flow through packed beds obtained from a second flight on the International Space Station are presented and analyzed. It is found that the gas hold-up is a function of the bed history at low liquid and gas flow rates whereas higher gas hold-up and pressure gradients are observed for the test conditions following a liquid only pre-flow compared to the test conditions following a gas only pre-flow period. Over the range of flow rates tested, the capillary force is the dominant contributor to the pressure gradient and is found to be linear with the superficial liquid velocity but is a much weaker function of the superficial gas velocity. The capillary contribution is also a function of the particle size and varies approximately inversely with the particle diameter within the range of the test conditions.

Effect of Solid Particles on the Gas Hold Up in the Fluidized Bed Columns: Experimental and Mathematical Studies

The present research investigated the effect of solid properties on the gas holdup of the fluidization bed bubble columns (FBCS). All experiments were performed in the constant clear tap water of 80 cm height. The range of solid particle diameters was 0.7 – 2 mm with two different densities of 1075 and 1200 kg/m3, superficial air velocities 4 – 7 cm/s. It was observed that there are proportional relationships between superficial gas velocity and particle diameter with the gas holdup. While an inverse relationship between solid concentration and particle density with the gas holdup. Mathematical and statistical analysis was also used as a powerful way to represent the gas hold up as a function of different operating conditions.

Numerical and orthogonal study on Optimization analysis of structure parameters of bubble breaker for Electrical Submersible Pump system

Under slug flow conditions, electrical submersible pumps (ESPs) show a low efficiency due to Taylor bubbles, which cause pressure surging and gas pockets and the further deterioration of pressure boosting ability. In this study, a novel downhole bubble breaker is designed for mitigating the impact in ESP under slug flow conditions. The CFD-PBM coupled approach was employed to calculate the bubble breaker's average bubble diameter to evaluate its efficiency. Meanwhile, experimental studies were conducted and compared with numerical results. Also, MATLAB and DIP-image technology was employed to calculate the bubble diameter. Compared with experimental results, the simulation results agree well. Furthermore, the novel bubble breaker's performance was studied by orthogonal approach. The best result of range analysis is A2B3C4D1E4 (a = 30°, L = 300 mm, R = 2:1, vsg = 0.2 m/s, and vsl = 0.08 m/s), and sensitively analysis results present that the range of impact intensity are A (inlet angle) > E (superficial gas velocity) > B (total length) > D (superficial liquid velocity) > C (ratio of the gas–liquid channel). The optimal structure's bubble diameters are all less than that of the original structure, with a superficial gas velocity range of 0.2–0.6 m/s. The downstream bubble diameter of the optimal bubble is about 31.6% lower than the original structure at the maximum value point.

Analysis of the Dynamics of Rougher Cells on the Basis of Phenomenological Models and Discrete Event Simulation Framework

Due to the increase in the amount of copper sulphide minerals processed through concentration processes and the need to improve the efficiency of these production processes, the development of theoretical models is making an important contribution to generating a better understanding of their dynamics, making it possible to identify the optimal conditions for the recovery of minerals, the impact of the independent variables in the responses, and the sensitivity of the recovery to variations in both the input variables and the operational parameters. This paper proposes a method for modeling, sensitizing, and optimizing the mineral recovery in rougher cells using a discrete event simulation (DES) framework and the fitting of analytical models on the basis of operational data from a concentration pilot plant. A sensitivity analysis was performed for low, medium, and high levels of the operative variables and/or parameters. The outcomes of the modeling indicate that the optimum mineral recovery is reached at medium levels of the flow rate of gas, bubble size, turbulence dissipation rate, surface tension, Reynolds number of bubble, bubble–particle contact angle, superficial gas velocity and gas hold-up in the froth zone. Additionally, the optimal response is reached at maximum levels of particle size and density and at minimum levels of bubble speed, fluid kinematic viscosity and fluid density in the sampled range. Finally, the recovery has an asymptotic behavior over time; however, the optimum recovery depends on an economic analysis, examining the marginalization of the response over time in an operational context.

Measuring binary fluidization of non-spherical and spherical particles using machine learning aided image processing

The binary fluidization of Geldart-D type non-spherical wood particles and spherical LDPE particles was investigated in a laboratory-scale bed. The experiment was performed for varying static bed height, wood particles count, as well as superficial gas velocity. The LDPE velocity field were quantified using Particle Image Velocimetry (PIV). The wood particles orientation and velocity are measured using Particle Tracking Velocimetry (PTV). A machine learning pixel-wise classification model was trained and applied to acquire wood and LDPE particle masks for PIV and PTV processing, respectively. The results show significant differences in the fluidization behavior between LDPE only case and binary fluidization case. The effects of wood particles on the slugging frequency, mean, and variation of bed height, and characteristics of the particle velocities/orientations were quantified and compared. This comprehensive experimental dataset serves as a benchmark for validating numerical models.

Hydrodynamics and Mass Transfer in a Concentric Internal Jet-Loop Airlift Bioreactor Equipped with a Deflector

The gas–liquid hydrodynamics and mass transfer were studied in a concentric tube internal jet-loop airlift reactor with a conical bottom. Comparing with a standard design, the gas separator was equipped with an adjustable deflector placed above the riser. The effect of riser superficial gas velocity uSGR on the total gas holdup εGT, homogenization time tH, and overall volumetric liquid-phase mass transfer coefficient kLa was investigated in a laboratory bioreactor, of 300 mm in inner diameter, in a two-phase air–water system and three-phase air–water–PVC–particle system with the volumetric solid fraction of 1% for various deflector clearances. The airlift was operated in the range of riser superficial gas velocity from 0.011 to 0.045 m/s. For the gas–liquid system, when reducing the deflector clearance, the total gas holdup decreased, the homogenization time increased twice compared to the highest deflector clearance tested, and the overall volumetric mass transfer coefficient slightly increased by 10–17%. The presence of a solid phase shortened the homogenization time, especially for lower uSGR and deflector clearance, and reduced the mass transfer coefficient by 15–35%. Compared to the gas–liquid system, the noticeable effect of deflector clearance was found for the kLa coefficient, which was found approx. 20–29% higher for the lowest tested deflector clearance.

A comparative evaluation of design factors on bubble column operation in photosynthetic biogas upgrading

Studies attempting to optimise photosynthetic biogas upgrading by simultaneous investigation of the bubble column-photobioreactor setup have experienced considerable variability in results and conclusions. To identify the sources of such variation, this work quantitatively compared seven design factors (superficial gas velocity; liquid to gas flow rate (L/G) ratio; empty bed residence time; liquid inlet pH; liquid inlet alkalinity; temperature; and algal concentration) using the L16 Taguchi orthogonal array as a screening design of experiment. Assessments were performed using the signal to noise (S/N) ratio on the performance of CO2 removal (CO­2 removal efficiency, CO2 absorption rate, and overall CO2 mass transfer coefficient) and O2 stripping (O2 concentration in biomethane and O2 flow rate in biomethane). Results showed that pH and L/G ratio were the most critical design factors. Temperature and gas residence times had minimal impact on the biomethane composition. The interactive effect between pH and L/G ratio was the most impactful, followed by the interactive effects between superficial gas velocity and L/G ratio and pH on CO2 removal efficiency. The impact of L/G ratio, algal concentration, and pH (in that order of impact) caused up to a 90% variation in oxygen content in biomethane. However, algal concentration had a diminishing role as the L/G ratio increased. Using only the statistically significant main effects and interactions, the biomethane composition (CO2% and O2%) was predicted with over 95% confidence through regression equations for superficial gas velocity up to 0.2 cm/s.

Homogeneous and re-circulatory gas–liquid flow in a bubble column: A numerical investigation using OpenFOAM

This work presents the influence of the sparger opening area, gas velocity, and bubble size on hydrodynamics and transition of the flow regime from uniform to re-circulatory in a rectangular bubble column using OpenFOAM. In the course of development of the model, the effect of several drag closures and lift on the predictability of the CFD model was studied by comparing the predictions with published experimental results. Reynolds number-based drag closure was found to be suitable for uniform sparger whereas Tsuchiya drag (Tsuchiya et al. in Chem Eng Sci 52:3053–3066, 1997. https://doi.org/10.1016/S0009-2509(97)00127-9) was used to simulate gas–liquid flow for other spargers. Simulations were performed for seven different spargers with opening area 18–100% (superficial gas velocity of 2.9–5.8 cm/s) and bubble size of 2–8 mm. The smaller opening area and higher gas velocity promote the re-circulatory flow in the bubble column. Change in bubble size affects the hydrodynamics due to change in lift and drag forces.