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Abstract
Two- and three-dimensional (2D and 3D) simulations of an airlift reactor under steady state conditions at low gas &ow rates
are presented. The simulations are based on a two-&uid model with a k– model for the turbulence and as little as possible ad
hoc closure terms. The results are compared with an one-dimensional mechanical energy balance and are found to be in good
agreement. The 2D results show sensitivity to the gas inlet geometry: whether or not the gas is partially sparged into the liquid
directly next to a wall a4ects the liquid velocity distribution and thereby the gas disengagement at the top of the airlift. The
three-dimensional calculations make a more realistic geometry possible. The friction in the system is found to be about a factor of
two larger in the 3D case at the same gas inlet conditions. For a given gas &ow rate, the mean gas fraction in the riser is the same
for the 2D and 3D simulations, the liquid circulation rate is about 30% higher in the 2D case than in the 3D one. A comparison
is made with experimental data obtained in an airlift of the same dimensions. The simulated overall gas fraction is in agreement
with the experimental 6ndings. The simulated super6cial velocity in the riser is compared to LDA data. For the lowest super6cial
velocities the LDA data coincide with the results from the 2D simulations, for higher gas &ow rates the LDA results switch over
towards the 3D results. ? 2001 Elsevier Science Ltd. All rights reserved.
0009-2509/01/$ - see front matter ? 2001 Elsevier Science Ltd. All rights reserved.
PII: S 0 0 0 9 - 2 5 0 9 ( 0 1 ) 0 0 2 2 2 - 6
6352 R. F. Mudde, H. E. A. Van Den Akker / Chemical Engineering Science 56 (2001) 6351–6358
been published that deal with the bubbly two-phase &ow in the present simulations:
in airlift reactors (see e.g. Sokolichin & Eigenberger,
@ṽr
1994; Cockx, LinCe, Roustan, Do-Quang, & Lazarova, Ĩ2 = −Ĩ1 = 2 1 fD ṽr + 2 1 CA + ṽ2 · ṽr
1997; Bagatin et al., 1999). In Cockx, Do-Quang, LinCe, @t
and Roustan (1999), hydrodynamics, mass transfer and + · 2 1 CA ṽ2 ṽr 2 − 1 ṽ1 ṽ2 2 · 2 : (1)
chemical reactions are calculated using CFD. In the
present paper, we present CFD simulations of the &ow in The drag is modeled as
a rectangular airlift reactor using a two-&uid model that 3 CD
takes into account the e4ects of the so-called drifting fD = |ṽ r |; |ṽ r | = ṽr · ṽr + ṽr · ṽr 2 (2)
4 d
velocity, virtual mass as well as bubble induced modi6-
cations of the turbulence. Both two-dimensional (using with
an in-house developed code (Lathouwers, 1999)) and 24
three-dimensional simulations (using FLUENT.V4.5) CD = (1 + 0:15 Re0:687 ): (3)
Re
are presented. The aim is to compare the two mutually
as well as with the simple one-dimensional mechanical The Reynolds number is based on the bubble motion
energy balance. Furthermore, we present gas fraction and and size. In Eq. (3) sometimes a term 1−1:7 is included.
liquid velocity data measured in an experimental facility Here, this is left out as the gas fractions are very low. The
of the same size as simulated. The liquid velocities were above drag formulation expresses that the slip velocity an
obtained by using laser doppler anemometry. individual bubble sees, is not equal to the relative mean
velocity, v2 − v1 . As a consequence of correlation between
the bubble motion and the turbulence in the liquid 6eld,
a drifting velocity, vd , has to be taken into account (see
2. Two-uid model Simonin & Viollet, 1990):
The two-&uid model can be derived by conditionally ṽr = [ṽ2 − ṽ1 ] − ṽd ;
ensemble averaging of the local instant conservation
˜t · 1 1
equations of single-phase &ow (Delhaye, 1974; Drew, ṽd = ṽ1 2 = − D̃ 12 2 − 1 ; (4)
1983). This results in two sets of mass, momentum and 2 1
energy balances that describe the &ow 6eld in terms of where the &uid-bubble turbulent dispersion tensor D12 t
is
averaged quantities. Both phases are treated incompress- expressed in terms of the turbulence characteristics of
ible in the sense that the densities of the gas and liquid the two phases, i.e. the covariance tensor between the
are constant. As the system is isothermal, the energy turbulent velocity &uctuations of the two phases and a
balances are not needed. Furthermore, mass transfer be- &uid-bubble turbulent characteristic time. The drifting
tween the bubble and water phases is neglected. The velocity is an important e4ect since the mass balances
turbulence in the continuous water phase is modeled us- do not contain a di4usive term that would be responsible
ing a modi6ed k– model, giving rise to two additional for the dispersion of the bubbles.
balance equations: for the turbulent kinetic energy, k1 , The second and third terms on the r.h.s. of Eq. (1)
and for the dissipation rate, . The governing equations represent the e4ects of virtual mass, while the last term
are summed up in Table 1 (continuous: k = 1, dispersed: accounts for the correlation between the instantaneous
k = 2). distribution of the particles and undisturbed &uid pressure
In Table 1 k is the volume fraction, k the density, &uctuations, i.e. the e4ects of turbulent pressure (for a de-
ṽk the (averaged) velocity of each phase, p the mean tailed discussion see e.g. Bel F’Dhila & Simonin, 1992).
pressure of phase 1, ˜ ˜k the (molecular) shear stress and
Ĩk the interfacial momentum transfer between the phases
2.2. Turbulence modeling
that remains after subtraction of the mean pressure of the
continuous phase; obviously 2k=1 Ĩk = 0. The quantity In k– type turbulence models, the terms
k1 and
ṽk is the &uctuating part of the local instantaneous ve- denote the ordinary one-phase production and dissipation
locity of phase k, de6ned as the di4erence between the terms. The terms
ki 1 and
i include the e4ect of the in-
local instantaneous and the ensemble averaged velocity. terfaces on the turbulence of the carrier phase. The for-
The terms denoted by
represent production of turbu- mer is given by (Bel F’Dhila & Simonin, 1992):
lent kinetic energy and dissipation. 2
ki 1 = 2 1 fD [ṽ1 · ṽ2 2 − 2k1 + ṽd · ṽr ]
2 + 1 CA
2.1. Interfacial momentum transfer (5)
Ĩk accounts for drag, virtual mass e4ects and turbulent with CA being the added-mass coeFcient, taken equal to
pressure. The lift force has not been taken into account 0.5. The latter is modeled according to Elgobashi and
R. F. Mudde, H. E. A. Van Den Akker / Chemical Engineering Science 56 (2001) 6351–6358 6353
Table 1
Two-&uid equations
D k k k
Mass =0
Dt
Dk k k ṽk
Momentum = − k p + k k g̃ − · k [˜
˜k + ṽk ṽk k ] + Ĩk
Dt
D 1 1 1 k1 t
Kin. energy = · 1 1 k1 + 1
k1 +
ki 1
Dt k 1
D 1 1 1 t
Dissipation = · (1 1 ) + 1
+
i
Dt
Abou-Arab (1983):
i = C; 3
ki 1 : (6)
k1
For a more complete discussion, see e.g. Thai Van,
Minier, Simonin, Freydier, and Olive (1994); Bel F’Dhila
and Simonin (1992) or Lathouwers (1999).
F 1 2
12 = + CA ;
fD 1
(7) 3. Airlift geometry
t t1 2 −1=2
12 = [1 + C r ]
k 1 The airlift is rectangular in shape, with a central riser
with r being the ratio of the characteristic time of the en- and two downcomer channels, one at each side of the
ergetic turbulent eddies to the characteristic transit time, riser, see Fig. 1. Air and water are taken as the two
t12 , required for the bubbles to cross the large eddies: phases.
The depth of the reactor is 12 cm. The riser and down-
t |ṽr |
comer are 13 and 10 cm in width, respectively. The height
r = t1 = : (8)
12 2
k of the bubbly mixture is 6xed at 102 cm for all simula-
3 1
tions and experiments reported. Each internal wall sep-
The parameter C is set at 0.45 in the direction parallel arating the riser from the downcomer has a width of
to the mean relative velocity and at 1.80 in the normal 0:5 cm; it starts at a height of 10 cm above the bottom
directions. and ends 12 cm below the free surface of the mixture.
Finally, the turbulent kinetic energy of the dispersed The sparger is located in the bottom part of the riser. It
phase and the covariance ṽ1 · ṽ2 2 is given by is a rectangular box with the same cross-sectional area
2
b + r as the riser and a height of 6 cm. The gas enters the riser
k2 = k1 ; (9)
1+ r through the porous top lid of this box at 16 cm above the
bottom of the airlift. The water circulation from down-
b+ r comer into the riser is made possible by having 4 × 4 &ow
ṽ1 · ṽ2 2 = 2k1 ; (10)
1+ r channels vertically through the sparger-box. At the bot-
r = t12 =F12 ; (11) tom, these channels are rectangular and ‘6ll’ the entire
cross-section. At the top of the box, their cross-section is
1 + CA circular with a diameter of 2:54 cm. The pitch is 3:04 cm;
b= : (12)
2 =1 + CA the minimum distance to the wall is 0:5 cm. This way,
6354 R. F. Mudde, H. E. A. Van Den Akker / Chemical Engineering Science 56 (2001) 6351–6358
the liquid enters the riser with vertical velocities only and
does not disturb the homogeneous gas distribution. The
height of the bubble mixture in the riser is 74 cm. The
air is introduced in the form of spherical bubbles with an
equivalent diameter of 3 mm.
3.1. Simulations
Fig. 3. Liquid velocity 6eld and gas fraction distribution for 2D-simulations at Ugas; R = 0:58 cm=s: (a) sparger touches internal wall (2Da),
(b) water channel next to internal wall (2Dw).
rate, gas is dragged into the downcomer at lower values escape completely from the increased liquid &ow at the
of the gas &ow in case of the sparger touching the wall. exit of the riser at the higher velocities.
Indeed, the results of 2Dw are closer to the experiment
than the 2Da ones. Already at a super6cial gas velocity of
1:15 cm=s in case 2Da, a signi6cant gas fraction is found 5.2. Three-dimensional simulations
at the entrance of the downcomer, whereas in case 2Dw
gas does not enter the downcomer at all. The latter is in The three-dimensional simulations are performed us-
reasonable agreement with the experiments. The size of ing FLUENT.V4.5. Only one-quarter of the reactor is
the circulation cell at the entrance of the downcomer is simulated: the vertical plane through the riser as well as
overpredicted by case 2Da. This is due to the liquid ve- the vertical plane between front and back wall through
locity being high at the internal wall side of the riser exit. the riser and both downcomers are assumed to be planes
In both cases the mixing of the separate bubble streams of symmetry. Note that the two-&uid modeling used by
is relatively slow: over roughly 1=3 of the riser the indi- FLUENT.V4.5 deviates slightly from the model used in
vidual plumes can still be seen. the in-house developed 2D code. The production of tur-
For the 2Dw-cases, the mechanical energy balance has bulence by the gas–liquid interphase does not contain the
been used to calculate the liquid &ow rate and the mean 6rst factor on the r.h.s. of Eq. (5). This is, for the ab-
gas fraction in the riser. Compared to the 3D case, the solute value of the bubble induced production term, a
friction is lower as the front and back wall are absent. Fur- not-negligible di4erence as the virtual mass coeFcient is
thermore, the friction at the top of the water channels in of order 1. Furthermore, the interfacial drag coeFcient
the sparger is less. An e4ective value of K = 2:7 is used. fD is based on the relative mean velocity rather than on
The results are given in Fig. 4. The agreement is quite the slip velocity corrected for the drifting velocity. Fi-
good on both the liquid &ow rate and the mean riser gas nally, FLUENT.V4.5 does not use the tvd-schemes.
fraction up to a super6cial gas velocity of 1:0 cm=s. Be- The 3D base case grid has 104 × 36 × 10 (= height ×
yond that, the mechanical energy balance predicts higher width × depth, including walls, free surface and
liquid circulation rates. This is caused by gas bubbles en- symmetry planes) grid cells, giving a cell size of
trained in the downcomer: the mechanical energy balance Uh = 1 cm; Uw = 0:5 cm; Ud = 0:75 cm. A (false)
used here assumes that the downcomer is bubble free. time step of 10 ms is choosen. As in the 2D simulations
The simulation shows, that the gas bubbles can no longer this is based on the convergence behavior. A typical
6356 R. F. Mudde, H. E. A. Van Den Akker / Chemical Engineering Science 56 (2001) 6351–6358
Fig. 4. Comparison of mechanical energy balance and CFD simulations for various gas &ow rates. The open squares show the sensitivity in the
3D simulations to grid doubling in the x; y; z directions, respectively; the diamonds represent the riser velocity obtained from the LDA-exp.
Fig. 5. Sparger geometry: (a) top view of checker board con6guration of the gas inlet: i = inlet (gray), L = life cell (white), wall = front wall
(dark), internal wall = wall separating left downcomer from riser (dark), symm = symmetry plane (light gray); (b) cells of the inlet neighboring
a life cell are split, outer cells are set to wall.
simulation on the standard grid used about 2 days of wall liquid velocity pro6les show similarities with case 2Da.
clock time on a 450 MHz PC. However, no gas is dragged into the downcomer at the
Originally, the aerating cells at the outside of a sparging gas &ow rates investigated.
area were directly connected to life cells that form the
&ow channels through the sparger. As this con6guration 5.2.1. Comparison simulations and energy balance
led to convergence problems, the outer cells of a sparger A comparison between simulated circulation velocities
area were split in the horizontal planes such that the inner and calculated from the mechanical energy balance shows
parts were still sparging and the outer parts were turned that the two are in agreement when an e4ective friction
into walls (see Fig. 5). This re6nement resulted in a grid coeFcient of 5 is taken, which is close to the estimated
of h × w × d = 104 × 44 × 14. Fig. 6 gives the gas fraction value of 4.3. However, the simulated mean riser gas frac-
distribution and liquid velocity in a few representative tion is lower than the calculated ones. This is in contrast
planes (horizontal ones for the gas fraction, vertical for with the 2D simulations, where both the liquid circula-
the velocity). Again the in&uence of the separate plumes tion rate and the mean gas fraction can be made to agree
can be seen high in the riser. Furthermore, the gas fraction with the mechanical energy balance. In the 3D case, the
above the two air inlet parts touching the internal wall is individual plumes penetrate further into the riser. This is
higher than at other positions in the same horizontal plane. probably causing the missmatch between simulations and
Once gas moves along the wall, it is not easily mixed one-dimensional analysis (where the riser gas fraction is
into the bulk. This a4ects the liquid velocity distribution assumed to be uniform).
as can be seen in Fig. 6b. The velocity is larger close To test the accuracy, simulations with a doubling of
to the internal wall than in the center of the riser. This the grid in the x; y and z directions, respectively, are per-
e4ect is stronger in vertical planes that cut through the formed. The in&uence is small, see Fig. 6 at a super6cial
sparger touching the internal wall (k = 3 in Fig. 6b). The gas velocity of 0:374 cm=s.
R. F. Mudde, H. E. A. Van Den Akker / Chemical Engineering Science 56 (2001) 6351–6358 6357
Fig. 6. Gas fraction and liquid velocity distribution for a 3D-simulation at Ugas; R = 0:374 cm=s: (a) gas fraction; (b) liquid velocity.
and dissipation by the bubbles. The results are found to Dhaouadi, H., Poncin, S., Hornut, J., Wild, G., Oinas, P., & Korpijari,
be sensitive to the exact geometry of the gas sparger. The J. (1997). Mass transfer in an external-loop airlift reactor:
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weak to eliminate the inlet e4ect. This has consequences Drew, D. (1983). Mathematical modelling of two-phase &ow. Annual
for the liquid velocity distribution, that in its turn a4ects Review of Fluid Mechanics, 15, 261–291.
the disengagement of the bubbles at the top of the air- Elgobashi, S., & Abou-Arab, T. (1983). A two-equation turbulence
lift. The simulations show a reasonable to good agree- model for two-phase &ows. Physics of Fluids, 26(4), 931–938.
ment with predictions of the riser gas fraction and liq- Hsu, Y., & Dudukovic, M. P. (1980). Gas holdup and liquid
recirculation in gas-lift reactors. Chemical Engineering Science,
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model. The two-dimensional simulations do predict the Lathouwers, D. (1999). Modelling and simulation of turbulent
right behavior, albeit that the circulation rate is overpre- bubbly 8ow. Ph.D. Thesis, Delft University of Technology, The
dicted and consequently the gas fraction underpredicted Netherlands.
due to the lower friction present in a 2D system. The in- Muroyama, K., Norieda, T., Morioka, A., & Tsuji, T. (1999).
Hydrodynamics and computer simulation of an ozone oxidation
vestigation indicates that CFD of airlift reactors can be reactor for treating drinking water. Chemical Engineering Science,
used to model, design or tune airlift reactors. A detailed 54, 5285–5292.
comparison with experiments is needed to see whether or Oey, R., Mudde, R., Portela, L., & Van den Akker, H. (2001).
not the details of the &ow are simulated well. Simulation of a slurry airlift using a two-&uid model. Chemical
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