Design of Multiphase Reactors
1. Auflage März 2015
536 Seiten, Hardcover
Wiley & Sons Ltd
Kurzbeschreibung
This resource offers a primer on simple design methods for multiphase reactors in the chemical process industries, particularly the fine chemicals industry. It provides the process design engineer with simple yet theoretically sound procedures. Different types of multiphase reactors are dealt with on an individual basis. The book focuses on the problem of predicting mass transfer rates in these reactors. It also contains finally worked examples that clearly illustrate how a highly complex MPR like the Stirred Tank Reactor (STR) can be designed using simple correlations which need only a scientific calculator.
ISBN:
978-1-118-80756-9
John Wiley & Sons
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
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
1.4 Parameters Concerning Catalyst Effectiveness in Industrial Operations 17
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
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
3.4 Some Examples of Large-Scale Applications of Multiphase Reactors 55
Nomenclature 80
References 81
4 Turbulence: Fundamentals and Relevance to Multiphase Reactors 87
4.1 Introduction 87
4.2 Fluid Turbulence 88
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
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
6.4 Correlations Based on Hydrodynamic/Turbulence Regime Similarity 116
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 (µG) 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
8.3 Advantages of the Venturi Loop Reactor: A Detailed Comparison 323
8.4 The Ejector-Based Liquid Jet Venturi Loop Reactor 326
8.5 The Ejector-Diffuser System and Its Components 332
8.6 Hydrodynamics of Liquid Jet Ejector 333
8.7 Design of Venturi Loop Reactor 358
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
9.2 Mechanism of Gas Induction 409
9.3 Classification of Gas-Inducing Impellers 410
9.4 Multiple-Impeller Systems Using 2-2 Type Impeller for Gas Induction 429
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
Respectively) 441
Nomenclature 443
References 446
10 Two- and Three-Phase Sparged Reactors 451
10.1 Introduction 451
10.2 Hydrodynamic Regimes in TPSR 452
10.3 Gas Holdup 457
10.4 Solid-Liquid Mass Transfer Coefficient (KSL) 466
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
10.9 TPSR (Loop) with Internal Draft Tube (BCDT) 481
Nomenclature 493
References 496
Index 505
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
1.4 Parameters Concerning Catalyst Effectiveness in Industrial Operations 17
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
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
3.4 Some Examples of Large-Scale Applications of Multiphase Reactors 55
Nomenclature 80
References 81
4 Turbulence: Fundamentals and Relevance to Multiphase Reactors 87
4.1 Introduction 87
4.2 Fluid Turbulence 88
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
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
6.4 Correlations Based on Hydrodynamic/Turbulence Regime Similarity 116
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 (µG) 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
8.3 Advantages of the Venturi Loop Reactor: A Detailed Comparison 323
8.4 The Ejector-Based Liquid Jet Venturi Loop Reactor 326
8.5 The Ejector-Diffuser System and Its Components 332
8.6 Hydrodynamics of Liquid Jet Ejector 333
8.7 Design of Venturi Loop Reactor 358
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
9.2 Mechanism of Gas Induction 409
9.3 Classification of Gas-Inducing Impellers 410
9.4 Multiple-Impeller Systems Using 2-2 Type Impeller for Gas Induction 429
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
Respectively) 441
Nomenclature 443
References 446
10 Two- and Three-Phase Sparged Reactors 451
10.1 Introduction 451
10.2 Hydrodynamic Regimes in TPSR 452
10.3 Gas Holdup 457
10.4 Solid-Liquid Mass Transfer Coefficient (KSL) 466
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
10.9 TPSR (Loop) with Internal Draft Tube (BCDT) 481
Nomenclature 493
References 496
Index 505
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.