BUBBLE COLUMN REACTOR

INTRODUCTION
A bubble column reactor is an apparatus used for gas-liquid reactions first applied by
Helmut Gerstenberg. It consists of vertically arranged cylindrical columns. The
introduction of gas takes place at the bottom of the column and causes
a turbulent stream to enable an optimum gas exchange. It is built in numerous forms of
construction. The mixing is done by the gas sparging and it requires less energy
than mechanical stirring. The liquid can be in parallel flow or counter-current.
Bubble column reactors belong to the general class of multiphase reactors which
consist of three main categories namely, the trickle bed reactor (fixed or packed
bed), fluidized bed reactor, and the bubble column reactor.
They are used especially in chemical processes involving reactions such as oxidation,
chlorination, alkylation, polymerization and hydrogenation, in the manufacture
of synthetic fuels by gas conversion processes and in biochemical processes such
as fermentation and biological wastewater treatment.

THEORY
The fluid dynamic characterization of bubble column reactors has a significant effect on
its the operation and performance. According to literature, the experimental results
obtained
by
parameter
investigations,
strictly
depend
on
the regime prevailing in the column. The flow regimes in bubble columns are
classified and maintained according to the superficial gas velocity employed in
the column. Three types of flow regimes are commonly observed in bubble columns
which are the Homogeneous (bubbly flow) regime; the Heterogeneous (mixed) regime
and Recirculating flow regime. There also exists the so-called foaming regime which is
not so commonly encountered in bubble columns.
The following parameters are important for understanding the theory and
hydrodynamics of a bubble column reactor :
1. Gas holdup : Gas holdup is a dimensionless key parameter for design purposes
that characterizes transport phenomena of bubble column systems. It is basically
defined as the volume fraction of gas phase occupied by the gas bubbles.

2. Superficial gas velocity : Superficial gas velocity is the average velocity of the gas
that is sparged into the column which is simply expressed as the volumetric flow
rate divided by the cross-sectional area of the column. Gas holdup in bubble
columns depends mainly on superficial gas velocity.
3. Liquid phase properties : The liquid phase property has an impact on bubble
formation and/or coalescing tendencies and hence is an important factor
affecting gas holdup. An increase in liquid viscosity results in large bubbles and
thus higher bubble rising velocities and lower gas holdup [68]. It is also reported
that adding a small amount of a surface acting material (surfactant) to water,
results in significantly higher gas holdup values. Moreover, the presence of
electrolyte or impurities also increases gas holdup.
4. Gas sparger : Gas sparger type is an important parameter that can alter bubble
characteristics which in turn affects gas holdup values and thus many other
parameters characterizing bubble columns. The sparger used definitely
determines the bubble sizes observed in the column. Small orifice diameter
plates enable the formation of smaller sized bubbles. Some common gas sparger
types that are used in literature studies are perforated plate, porous plate,
membrane, ring type distributors and arm spargers.
The Three Regimes :

Fig 1 : Flow pattern v/s superficial gas velocity & superficial gas velocity v/s diameter

At a small volumetric flow rate of gas the bubbles leaving the holes of spargers flow
upwards separately at a uniform velocity and gas hold-up in the column steadily
increases with an increase in the gas velocity. The gas hold-up is proportional to the gas
velocity. This regime is called the bubbling (homogeneous) flow regime.
At a further increase of gas flow velocity deviations from this ideal case take place.
Particular bubbles begin to coalesce into large bubbles, which flow in the central part of
the column. These bubbles break down and coalesce several times during the flow.
Such a gas flow causes significant liquid flow in the column and an abrupt increase
of turbulence of the liquid phase. Near the maximum gas hold-up there is
a large flow of liquid upward in the central part of the column and flow down near the
column wall. The latter flow slows down or even stops the flow of gas bubbles near
the column wall. At a further increase in the gas flow velocity the gas hold-up reaches
the minimum value. This follows from the fact that large bubbles flow at a high velocity,
much higher than small bubbles.
A further increase in gas flow velocity causes a steady increase in gas hold-up in
the column. Besides the large number of small gas bubbles, there are large bubbles
which coalesce, thus forming a continuous gas phase. It is irregular and changes its
shape continuously. In this range of gas velocity a high liquid circulation in the column is
observed.
For example, in the investigations carried out in a column of diameter 5.5 m and liquid
height 7 m, with superficial gas velocity ranging from 2.4 to 8.5 cm/s, the liquid velocity
in the column axis changes from 52 to 115 cm/s. This regime is called a churn-turbulent
(heterogeneous) flow regime or sometimes a recirculating flow regime. The flow
regimes depend not only on gas flow velocity but also on other values, such as the
physicochemical properties of the liquid, the type of gas distributor (single or
multinozzle), the size of orifices in the gas distributor, the column diameter, the liquid
flow velocity, etc. For example, when gas is fed to the column by a sintering plate with
orifices up to 150 mm, bubble flow regime takes place at a gas flow velocity of up to 8
cm/s. When a plate with an orifice diameter over 1 mm is used, bubbling flow is
observed at a gas flow velocity about 2 cm/s. In industrial columns usually the regime of
the liquid recirculating flow is observed because the gas flow velocities used in these
columns are significant.

TYPES
Several types of bubble column reactor are used in practice, some of which are shown in
Figure 2.

Fig 2 : Types of Bubble column reactors

OPERATION
Bubble columns are gas-liquid systems in which a gas is dispersed through a sparger
and bubbles through a liquid in a vertical cylindrical column. When suspended fine solids
are present in liquid, they form a slurry phase. Accordingly, they can be called either
two-phase or three-phase (slurry) bubble column.
The liquid/slurry phase flow can be either : (1) co-current , (2) counter-current ,(3) batch
mode with respect to the gas flow.
The size of the solid particles ranges from 5 to 150 m, with solids loading up to 50 % .
The gas phase contains one or more reactants, while the liquid phase usually contains
product and/or reactants (or is sometimes inert). The solid particles are typically
catalyst.
In these reactors, momentum is transferred from the faster, upward moving gas phase
to the slower liquid/slurry phase. Generally, the operating liquid superficial velocity (in
the range of 0 to 2 cm/s) is an order of magnitude smaller than the superficial gas
velocity (1 to 50 cm/s). Hence, the hydrodynamics of such reactors are controlled mainly
by the gas flow.
Although bubble column reactors are simple in construction, proper design and scale-up
of such reactors require a thorough understanding of the prevailing hydrodynamic and
mixing characteristics at conditions similar to the targeted process. The hydrodynamics
of such reactors affect the mixing intensity and gas-liquid interfacial area, which affect
the transport coefficients, and hence the conversion and selectivity of the reactor.
Hydrodynamic behavior in a bubble column reactor is complex, since the fluid phases
involved are characterized by very different masses, and one is more compressible than
the other.
The hydrodynamics, reactor performance, operation, design and scale-up depend on :
1) Various design parameters (e.g., reactor geometry, internals, sparger design, etc.)
2) Operating variables (e.g., reactor pressure and temperature, gas and liquid/slurry
flow rates, catalyst size and loading, etc.)
3) Phase properties and kinetics.
4) Heat and mass transfer characteristics
5) Mixing characteristics

Note: In slurry bubble column reactors, the ability to achieve complete catalyst
suspension and the desired flow pattern of the liquid/solid phase is critical to the
targeted reactor performance.
Length to Diameter Ratio of Columns:
(1) Industrial bubble columns usually operate with a length-to-diameter ratio, or aspect
ratio of at least 5.
(2) In biochemical applications this value usually varies between 2 and 5.
Selection of column dimensions:
(1) The use of large diameter reactors is desired because large gas throughputs are
involved.
(2) Large reactor heights are required to obtain large conversion levels.
(3)There are also disadvantages brought about by the use of large diameter and tall
columns in terms of ease of operation. As a result it is necessary to talk about an
optimization process for best output.
Mode of operation for bubble columns:
(1) Continuous mode
The gas and the suspension flow concurrently upward into the column and the
suspension that leaves the column is recycled to the feed tank. The liquid superficial
velocity is maintained to be lower than the gas superficial velocity by at least an order of
magnitude.
(2) Semi-batch mode
The suspension is stationary, meaning zero liquid throughputs, and the gas is bubbled
upward into the column.

The liquid/slurry phase flow can be either : (1) co-current , (2) counter-current ,(3) batch
mode with respect to the gas flow.

Measuring devices and accessories:

(1)The gas flow into the column is measured via rotameter and the superficial gas
velocity is adjusted.
(2)The gas is distributed by a gas
distributor, which has different alternatives such as ring type,
perforated plate or arm distributor.
(3)An electric heater can be installed to maintain constant temperature in the column.
(4)The pressure measurement system may contain liquid manometers or pressure
transducers (pressure transmitters).Pressure measurements are used to estimate gas
holdup in the system.
(5)Thermocouples are used wherever temperature variation is needed to be recorded.
(6)Heat flux sensors may be used to estimate the heat flux and to measure the
corresponding heat transfer coefficients between the heated immersed object and
slurry or the slurry and wall.
(7)For better control and adjustment, the equipments are usually accompanied by PID
controllers.
(8)Data acquisition systemsmay be utilized for instantaneous parameter investigations,
for instance for recording the pressure fluctuations and estimation of instantaneous gas
holdups and bubble properties.

Gas Distribution:
Usually, the gas is dispersed to create small bubbles and distribute them uniformly over
the cross section of the equipment to maximize the intensity of mass transfer. The
formation of fine bubbles is especially desirable in coalescence hindered systems and in
the homogeneous flow regime .In principle, however, significant mass transfer can be
obtained at the gas distributor through a high local energy dissipation density. In most
cases, gas bubbles are generated by pores or holes or in the shear zone of a liquid
jet.
Figure below shows typical forms of static gas spargers, in which bubble formation
occurs without any additional energy supplied from outside. The simplest of these
devices, the dip tube (Fig. 3A), only gives an acceptably uniform gas distribution over the
cross section at some distance above the sparger. Perforated plates (Fig. 3B) and
perforated ring spargers (Fig. 3C) are more effective. Both of these require a certain
minimum gas flow rate to achieve uniform distribution and prevent the liquid from
getting into the sparger. Very fine bubbles can be generated by the use of porous plates
(Fig. 3D), but their pores are susceptible to fouling, and this type of sparger is seldom
used in full-scale equipment.

Figure 3 : Static gas spargers : A) Dip tube; B) Perforated plate; C) Perforated ring
sparger; D) Porous plate

Dynamic spargers offer an alternative to the static types. They use the power of a liquid
jet to disperse gas in a zone of high energy dissipation rate. Figure 4 illustrates several
frequently used dynamic gas spargers. The simple two-phase jet nozzle alone (Fig. 4A) or
with momentum-transfer tube (Fig. 4B) is not able to simultaneously disperse gas and
suck in the gas stream. This can be achieved, however, with the ejector jet nozzle (Fig.
4C), the ejector (Fig. 4D), and the Venturi tube (Fig. 4E). In nozzle selection the ratio of
the gas liquid volumetric flow rates must always be considered.
Common values lie between 0.5 and 2. However, much higher values can be achieved in
special cases with momentum-transfer tubes
.

Figure 4. Dynamic gas spargers

ADVANTAGES
Bubble column reactors owe their wide application area to a number of advantages they
provide both in design and operation as compared to other reactors. First of all, they have
excellent heat and mass transfer characteristics,meaning high heat and mass transfer
coefficients. Little maintenance and low operating costs are required due to lackof moving parts
and compactness, easy temperature control. The durability of the catalyst or other packing
material is high . Moreover,online catalyst addition and withdrawal ability and plug-free
operation are other advantages that render bubble columns as an attractive reactor choice.
The main advantages of this reactor type with respect with the conventional slurry bubble
column are:
1.no problems for separating catalyst from the liquid;
2.improved conversion and selectivity due to staging of the liquid phase;
3.no scale up problems because the hydrodynamics is dictated by the size of the open
channels of the catalytic structure
The main advantages over tricklebeds :
1. Lower pressure-drop even with 1 mm size particles
2. Excellent radial dispersion
3. Possibility of counter-current operation without flooding.

DISADVANTAGES
1. Considerable degree of back mixing in both the liquid and the gas phase
2. Short gas phase residence time
3. Higher pressure drop with respect to packed columns
4. Rapid decreasing of interfacial area above values of the aspect ratio greater than, say 12,
due to the increased rate of coalescence

APPLICATIONS
Bubble columns can be used:
1. As gas-liquid and gas-liquid-solid contactors in many chemical, petrochemical and
biochemical industries, such as absorption, oxidation, catalytic slurry reaction, coal
liquefaction, aerobic fermentation
2.For purification of nitroglycerin with water.
3.In the chemical industry for hydrogenation, oxidation, chlorination, and alkylation.
4.In the biotechnological field for effluent treatmet, single-cell protein productin, animal cell
culture, and antibiotic fermentation.
5. For radioactive elements because there are no moving parts.
6.As bioreactors in which microorganisms are utilized inorder to produce industrially valuable
products such as enzymes, proteins, antibiotics.
7.It is also used for Fischer-Tropsch synthesis,methanol synthesis, polymerisation of olefins ,
hydrotreating and conversion of petroleum residues.

LIST OF REFERENCES
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Se

http://en.wikipedia.org/wiki/Bubble_column_reactor
http://web.ist.utl.pt/ist11061/de/Equipamento/BubbleColumnReactors(review).pdf
http://www.sciencedirect.com/science/article/pii/S0009250906006610
http://www.sciencedirect.com/science/article/pii/S0009250914006873
http://www.sciencedirect.com/science/article/pii/S1385894714015587