Vishwas G. Pangarkar

Design of Multiphase Reactors

• Gebundenes Buch

Produktbeschreibung

Details simple design methods for multiphase reactors in the chemical process industries

Includes basic aspects of transport in multiphase reactors and the importance of relatively reliable and simple procedures for predicting mass transfer parameters
Details of design and scale up aspects of several important types of multiphase reactors
Examples illustrated through design methodologies presenting different reactors for reactions that are industrially important
Includes simple spreadsheet packages rather than complex algorithms / programs or computational aid

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Produktdetails

• Verlag: Wiley & Sons
• 1. Auflage
• Seitenzahl: 536
• Erscheinungstermin: 27. Januar 2015
• Englisch
• Abmessung: 241mm x 159mm x 35mm
• Gewicht: 838g
• ISBN-13: 9781118807569
• ISBN-10: 1118807561
• Artikelnr.: 41078907

Autorenporträt

Vishwas Govind Pangarkar was Professor and head of the Chemical Engineering Department of the University Institute of Chemical Technology in Mumbai, India. He has been actively engaged as a consultant in the chemical industry since 1974 for both Indian and overseas companies. He is the (co)author of three books and over 130 professional papers. He is the only Indian winner of both Herdillia and NOCIL Awards of The Indian Institute of Chemical Engineers, which are for excellence in such diverse fields as basic research and industrial innovations.

Inhaltsangabe

Foreword xv
Preface xvii
1 Evolution of the Chemical Industry and Importance of Multiphase Reactors
1
1.1 Evolution of Chemical Process Industries 1
1.2 Sustainable and Green Processing Requirements in the Modern Chemical
Industry 4
1.3 Catalysis 9
1.3.1 Heterogeneous Catalysis 11
1.3.2 Homogeneous Catalysis 16
1.4 Parameters Concerning Catalyst Effectiveness in Industrial Operations
17
1.4.1 Chemoselectivity 19
1.4.2 Regioselectivity 19
1.4.3 Stereoselectivity 19
1.5 Importance of Advanced Instrumental Techniques in Understanding
Catalytic Phenomena 20
1.6 Role of Nanotechnology in Catalysis 21
1.7 Click Chemistry 21
1.8 Role of Multiphase Reactors 22
References 23
2 Multiphase Reactors: The Design and Scale-Up Problem 30
2.1 Introduction 30
2.2 The Scale-Up Conundrum 31
2.3 Intrinsic Kinetics: Invariance with Respect to Type/Size of Multiphase
Reactor 34
2.4 Transport Processes: Dependence on Type/Size of Multiphase Reactor 34
2.5 Prediction of the Rate-Controlling Step in the Industrial Reactor 35
2.6 Laboratory Methods for Discerning Intrinsic Kinetics of Multiphase
Reactions 35
2.6.1 Two-Phase (Gas-Liquid) Reaction 35
2.6.2 Three-Phase (Gas-Liquid-Solid) Reactions with Solid Phase Acting as
Catalyst 41
Nomenclature 44
References 45
3 Multiphase Reactors: Types and Criteria for Selection for a Given
Application 47
3.1 Introduction to Simplified Design Philosophy 47
3.2 Classification of Multiphase Reactors 48
3.3 Criteria for Reactor Selection 48
3.3.1 Kinetics vis-à-vis Mass Transfer Rates 49
3.3.2 Flow Patterns of the Various Phases 50
3.3.3 Ability to Remove/Add Heat 50
3.3.4 Ability to Handle Solids 53
3.3.5 Operating Conditions (Pressure/Temperature) 54
3.3.6 Material of Construction 54
3.4 Some Examples of Large-Scale Applications of Multiphase Reactors 55
3.4.1 Fischer-Tropsch Synthesis 55
3.4.2 Oxidation of p-Xylene to Purified Terephthalic Acid for Poly(Ethylene
Terephthalate) 67
Nomenclature 80
References 81
4 Turbulence: Fundamentals and Relevance to Multiphase Reactors 87
4.1 Introduction 87
4.2 Fluid Turbulence 88
4.2.1 Homogeneous Turbulence 89
4.2.2 Isotropic Turbulence 90
4.2.3 Eddy Size Distribution and Effect of Eddy Size on Transport Rates 90
Nomenclature 91
References 91
5 Principles of Similarity and Their Application for Scale-Up of Multiphase
Reactors 93
5.1 Introduction to Principles of Similarity and a Historic Perspective 93
5.2 States of Similarity of Relevance to Chemical Process Equipments 94
5.2.1 Geometric Similarity 95
5.2.2 Mechanical Similarity 96
5.2.3 Thermal Similarity 100
5.2.4 Chemical Similarity 100
5.2.5 Physiological Similarity 101
5.2.6 Similarity in Electrochemical Systems 101
5.2.7 Similarity in Photocatalytic Reactors 102
Nomenclature 102
References 104
6 Mass Transfer in Multiphase Reactors: Some Theoretical Considerations 106
6.1 Introduction 106
6.2 Purely Empirical Correlations Using Operating Parameters and Physical
Properties 107
6.3 Correlations Based on Mechanical Similarity 108
6.3.1 Correlations Based on Dynamic Similarity 108
6.4 Correlations Based on Hydrodynamic/Turbulence Regime Similarity 116
6.4.1 The Slip Velocity Approach 116
6.4.2 Approach Based on Analogy between Momentum and Mass Transfer 132
Nomenclature 135
References 138
7A Stirred Tank Reactors for Chemical Reactions 143
7A.1 Introduction 143
7A.1.1 The Standard Stirred Tank 143
7A.2 Power Requirements of Different Impellers 147
7A.3 Hydrodynamic Regimes in Two-Phase (Gas-Liquid) Stirred Tank Reactors
148
7A.3.1 Constant Speed of Agitation 150
7A.3.2 Constant Gas Flow Rate 150
7A.4 Hydrodynamic Regimes in Three-Phase (Gas-Liquid-Solid) Stirred Tank
Reactors 153
7A.5 Gas Holdup in Stirred Tank Reactors 155
7A.5.1 Some Basic Considerations 155
7A.5.2 Correlations for Gas Holdup 164
7A.5.3 Relative Gas Dispersion (N/NCD) as a Correlating Parameter for Gas
Holdup 165
7A.5.4 Correlations for NCD 166
7A.6 Gas-Liquid Mass Transfer Coefficient in Stirred Tank Reactor 166
7A.7 Solid-Liquid Mass Transfer Coefficient in Stirred Tank Reactor 175
7A.7.1 Solid Suspension in Stirred Tank Reactor 175
7A.7.2 Correlations for Solid-Liquid Mass Transfer Coefficient 191
7A.8 Design of Stirred Tank Reactors with Internal Cooling Coils 194
7A.8.1 Gas Holdup 194
7A.8.2 Critical Speed for Complete Dispersion of Gas 194
7A.8.3 Critical Speed for Solid Suspension 195
7A.8.4 Gas-Liquid Mass Transfer Coefficient 195
7A.8.5 Solid-Liquid Mass Transfer Coefficient 196
7A.9 Stirred Tank Reactor with Internal Draft Tube 196
7A.10 Worked Example: Design of Stirred Reactor for Hydrogenation of
Aniline to Cyclohexylamine (Capacity: 25000 Metric Tonnes per Year) 198
7A.10.1 Elucidation of the Output 201
Nomenclature 203
References 206
7B Stirred Tank Reactors for Cell Culture Technology 216
7B.1 Introduction 216
7B.2 The Biopharmaceutical Process and Cell Culture Engineering 224
7B.2.1 Animal Cell Culture vis-à-vis Microbial Culture 224
7B.2.2 Major Improvements Related to Processing of Animal Cell Culture 225
7B.2.3 Reactors for Large-Scale Animal Cell Culture 226
7B.3 Types of Bioreactors 229
7B.3.1 Major Components of Stirred Bioreactor 230
7B.4 Modes of Operation of Bioreactors 230
7B.4.1 Batch Mode 231
7B.4.2 Fed-Batch or Semibatch Mode 232
7B.4.3 Continuous Mode (Perfusion) 233
7B.5 Cell Retention Techniques for Use in Continuous Operation in Suspended
Cell Perfusion Processes 233
7B.5.1 Cell Retention Based on Size: Different Types of Filtration
Techniques 234
7B.5.2 Separation Based on Body Force Difference 242
7B.5.3 Acoustic Devices 246
7B.6 Types of Cells and Modes of Growth 253
7B.7 Growth Phases of Cells 254
7B.8 The Cell and Its Viability in Bioreactors 256
7B.8.1 Shear Sensitivity 256
7B.9 Hydrodynamics 264
7B.9.1 Mixing in Bioreactors 264
7B.10 Gas Dispersion 273
7B.10.1 Importance of Gas Dispersion 273
7B.10.2 Effect of Dissolved Carbon Dioxide on Bioprocess Rate 275
7B.10.3 Factors That Affect Gas Dispersion 277
7B.10.4 Estimation of NCD 278
7B.11 Solid Suspension 279
7B.11.1 Two-Phase (Solid-Liquid) Systems 279
7B.11.2 Three-Phase (Gas-Liquid-Solid) Systems 280
7B.12 Mass Transfer 281
7B.12.1 Fractional Gas Holdup (¿G) 281
7B.12.2 Gas-Liquid Mass Transfer 281
7B.12.3 Liquid-Cell Mass Transfer 283
7B.13 Foaming in Cell Culture Systems: Effects on Hydrodynamics and Mass
Transfer 285
7B.14 Heat Transfer in Stirred Bioreactors 287
7B.15 Worked Cell Culture Reactor Design Example 291
7B.15.1 Conventional Batch Stirred Reactor with Air Sparging for
Microcarrier-Supported Cells: A Simple Design Methodology for Discerning
the Rate-Controlling Step 291
7B.15.2 Reactor Using Membrane-Based Oxygen Transfer 294
7B.15.3 Heat Transfer Area Required 294
7B.16 Special Aspects of Stirred Bioreactor Design 295
7B.16.1 The Reactor Vessel 296
7B.16.2 Sterilizing System 296
7B.16.3 Measurement Probes 296
7B.16.4 Agitator Seals 297
7B.16.5 Gasket and O-Ring Materials 297
7B.16.6 Vent Gas System 297
7B.16.7 Cell Retention Systems in Perfusion Culture 297
7B.17 Concluding Remarks 298
Nomenclature 298
References 301
8 Venturi Loop Reactor 317
8.1 Introduction 317
8.2 Application Areas for the Venturi Loop Reactor 317
8.2.1 Two Phase (Gas-Liquid Reactions) 318
8.2.2 Three-Phase (Gas-Liquid-Solid-Catalyzed) Reactions 319
8.3 Advantages of the Venturi Loop Reactor: A Detailed Comparison 323
8.3.1 Relatively Very High Mass Transfer Rates 323
8.3.2 Lower Reaction Pressure 324
8.3.3 Well-Mixed Liquid Phase 325
8.3.4 Efficient Temperature Control 325
8.3.5 Efficient Solid Suspension and Well-Mixed Solid (Catalyst) Phase 325
8.3.6 Suitability for Dead-End System 326
8.3.7 Excellent Draining/Cleaning Features 326
8.3.8 Easy Scale-Up 326
8.4 The Ejector-Based Liquid Jet Venturi Loop Reactor 326
8.4.1 Operational Features 328
8.4.2 Components and Their Functions 328
8.5 The Ejector-Diffuser System and Its Components 332
8.6 Hydrodynamics of Liquid Jet Ejector 333
8.6.1 Flow Regimes 336
8.6.2 Prediction of Rate of Gas Induction 341
8.7 Design of Venturi Loop Reactor 358
8.7.1 Mass Ratio of Secondary to Primary Fluid 358
8.7.2 Gas Holdup 367
8.7.3 Gas-Liquid Mass Transfer: Mass Transfer Coefficient (kLa) and
Effective Interfacial Area (a) 376
8.8 Solid Suspension in Venturi Loop Reactor 385
8.9 Solid-Liquid Mass Transfer 388
8.10 Holding Vessel Size 389
8.11 Recommended Overall Configuration 389
8.12 Scale-Up of Venturi Loop Reactor 390
8.13 Worked Examples for Design of Venturi Loop Reactor: Hydrogenation of
Aniline to Cyclohexylamine 390
Nomenclature 395
References 399
9 Gas-Inducing Reactors 407
9.1 Introduction and Application Areas of Gas-Inducing Reactors 407
9.1.1 Advantages 408
9.1.2 Drawbacks 408
9.2 Mechanism of Gas Induction 409
9.3 Classification of Gas-Inducing Impellers 410
9.3.1 1-1 Type Impellers 410
9.3.2 1-2 and 2-2 Type Impellers 416
9.4 Multiple-Impeller Systems Using 2-2 Type Impeller for Gas Induction 429
9.4.1 Critical Speed for Gas Induction 431
9.4.2 Rate of Gas Induction (QG) 431
9.4.3 Critical Speed for Gas Dispersion 434
9.4.4 Critical Speed for Solid Suspension 436
9.4.5 Operation of Gas-Inducing Reactor with Gas Sparging 439
9.4.6 Solid-Liquid Mass Transfer Coefficient (KSL) 440
9.5 Worked Example: Design of Gas-Inducing System with Multiple Impellers
for Hydrogenation of Aniline to Cyclohexylamine (Capacity:
25000 Metric Tonnes per Year) 441
9.5.1 Geometrical Features of the Reactor/Impeller (Dimensions and
Geometric Configuration as per Section 7A.10 and Figure 9.9
Respectively) 441
9.5.2 Basic Parameters 442
Nomenclature 443
References 446
10 Two- and Three-Phase Sparged Reactors 451
10.1 Introduction 451
10.2 Hydrodynamic Regimes in TPSR 452
10.2.1 Slug Flow Regime 452
10.2.2 Homogeneous Bubble Flow Regime 452
10.2.3 Heterogeneous Churn-Turbulent Regime 454
10.2.4 Transition from Homogeneous to Heterogeneous Regimes 455
10.3 Gas Holdup 457
10.3.1 Effect of Sparger 458
10.3.2 Effect of Liquid Properties 458
10.3.3 Effect of Operating Pressure 460
10.3.4 Effect of Presence of Solids 461
10.4 Solid-Liquid Mass Transfer Coefficient (KSL) 466
10.4.1 Effect of Gas Velocity on KSL 466
10.4.2 Effect of Particle Diameter dP on KSL 467
10.4.3 Effect of Column Diameter on KSL 467
10.4.4 Correlation for KSL 468
10.5 Gas-Liquid Mass Transfer Coefficient (kLa) 468
10.6 Axial Dispersion 472
10.7 Comments on Scale-Up of TPSR/Bubble Columns 474
10.8 Reactor Design Example for Fischer-Tropsch Synthesis Reactor 474
10.8.1 Introduction 474
10.8.2 Physicochemical Properties 475
10.8.3 Basis for Reactor Design Material Balance and Reactor Dimensions 476
10.8.4 Calculation of Mass Transfer Parameters 476
10.8.5 Estimation of Rates of Individual Steps and Determination of the
Rate Controlling Step 478
10.8.6 Sparger Design 480
10.9 TPSR (Loop) with Internal Draft Tube (BCDT) 481
10.9.1 Introduction 481
10.9.2 Hydrodynamic Regimes in TPSRs with Internal Draft Tube 481
10.9.3 Gas-Liquid Mass Transfer 482
10.9.4 Solid Suspension 488
10.9.5 Solid-Liquid Mass Transfer Coefficient (KSL) 490
10.9.6 Correlation for KSL 490
10.9.7 Application of BCDT to Fischer-Tropsch Synthesis 491
10.9.8 Application of BCDT to Oxidation of p-Xylene to Terephthalic Acid
492
Nomenclature 493
References 496
Index 505