Pangarkar V.G. Design of Multiphase Reactors

John Wiley & Sons, Inc., 2015. — 535 pMultiphase reactors are widely used in the chemical industry. The design and scale-up of such reactors is always a difficult task and is not adequately covered in traditional chemical reaction engineering books. The book by Pangarkar is a welcome addition to this field and brings a new perspective of combining the theory with practice.
The book opens with examples of industrial applications and addresses many issues associated with the success of industrial multiphase processes, such as catalyst selection, selectivity, environmental issues. It proceeds then to address the key problem of design and scale-up. The transport–kinetic interaction is vital to understand the design of these reactors.ForewordEvolution of the Chemical Industry and Importance of Multiphase Reactors
Evolution of Chemical Process Industries,
Sustainable and Green Processing Requirements in the Modern Chemical Industry,
Catalysis,
Heterogeneous Catalysis,
Homogeneous Catalysis,
Parameters Concerning Catalyst Effectiveness in Industrial Operations,
Chemoselectivity,
Regioselectivity,
Stereoselectivity,
mportance of Advanced Instrumental Techniques in Understanding Catalytic Phenomena,
Role of Nanotechnology in Catalysis,
Click Chemistry,
Role of Multiphase Reactors,
References,
Multiphase Reactors: The Design and Scale-Up Problem
ntroduction,
The Scale-Up Conundrum,
ntrinsic Kinetics: Invariance with Respect to Type/Size of Multiphase Reactor,
Transport Processes: Dependence on Type/Size of Multiphase Reactor,
Prediction of the Rate-Controlling Step in the Industrial Reactor,
Laboratory Methods for Discerning Intrinsic Kinetics of Multiphase Reactions,
Two-Phase (Gas–Liquid) Reaction,
Three-Phase (Gas–Liquid–Solid) Reactions with Solid Phase
Acting as Catalyst,
Nomenclature,
References,
Multiphase Reactors: Types and Criteria for Selection for a Given Application
ntroduction to Simplified Design Philosophy,
Classification of Multiphase Reactors,
Criteria for Reactor Selection,
Kinetics vis-à-vis Mass Transfer Rates,
Flow Patterns of the Various Phases,
Ability to Remove/Add Heat,
Ability to Handle Solids,
Operating Conditions (Pressure/Temperature),
Material of Construction,
Some Examples of Large-Scale Applications of Multiphase Reactors,
Fischer–Tropsch Synthesis,
Oxidation of p-Xylene to Purified Terephthalic Acid for Poly(Ethylene Terephthalate),
Nomenclature,
References,
Turbulence: Fundamentals and Relevance to Multiphase Reactors
ntroduction,
Fluid Turbulence,
Homogeneous Turbulence,
sotropic Turbulence,
Eddy Size Distribution and Effect of Eddy Size on Transport Rates,
Nomenclature,
References,
Principles of Similarity and Their Application for Scale-Up of Multiphase Reactors
ntroduction to Principles of Similarity and a Historic Perspective,
States of Similarity of Relevance to Chemical Process Equipments,
Geometric Similarity,
Mechanical Similarity,
Thermal Similarity,
Chemical Similarity,
Physiological Similarity,
Similarity in Electrochemical Systems,
Similarity in Photocatalytic Reactors,
Nomenclature,
References,
Mass Transfer in Multiphase Reactors: Some Theoretical Considerations
ntroduction,
Purely Empirical Correlations Using Operating Parameters and Physical Properties,
Correlations Based on Mechanical Similarity,
Correlations Based on Dynamic Similarity,
Correlations Based on Hydrodynamic/Turbulence Regime Similarity,
The Slip Velocity Approach,
Approach Based on Analogy between Momentum and Mass
Transfer,
Nomenclature,
References,
Stirred Tank Reactors for Chemical Reactions
Introduction,
The Standard Stirred Tank,
Power Requirements of Different Impellers,
Hydrodynamic Regimes in Two-Phase (Gas–Liquid) Stirred Tank Reactors,
Constant Speed of Agitation,
Constant Gas Flow Rate,
Hydrodynamic Regimes in Three-Phase (Gas–Liquid–Solid) Stirred Tank Reactors,
Gas Holdup in Stirred Tank Reactors,
Some Basic Considerations,
Correlations for Gas Holdup,
Relative Gas Dispersion (N/NCD) as a Correlating Parameter for Gas Holdup,
Correlations for NCD,
Gas–Liquid Mass Transfer Coefficient in Stirred Tank Reactor,
Solid–Liquid Mass Transfer Coefficient in Stirred Tank Reactor,
Solid Suspension in Stirred Tank Reactor,
Correlations for Solid–Liquid Mass Transfer Coefficient,
Design of Stirred Tank Reactors with Internal Cooling Coils,
Gas Holdup,
Critical Speed for Complete Dispersion of Gas,
Critical Speed for Solid Suspension,
Gas–Liquid Mass Transfer Coefficient,
Solid–Liquid Mass Transfer Coefficient,
Stirred Tank Reactor with Internal Draft Tube,
Worked Example: Design of Stirred Reactor for Hydrogenation of Aniline to Cyclohexylamine (Capacity: 25,000 Metric Tonnes per Year),
Elucidation of the Output,
Nomenclature,
References,
Stirred Tank Reactors for Cell Culture Technology
Introduction,
The Biopharmaceutical Process and Cell Culture Engineering,
Animal Cell Culture vis-à-vis Microbial Culture,
Major Improvements Related to Processing of Animal Cell Culture,
Reactors for Large-Scale Animal Cell Culture,
Types of Bioreactors,
Major Components of Stirred Bioreactor,
Modes of Operation of Bioreactors,
Batch Mode,
Fed-Batch or Semibatch Mode,
Continuous Mode (Perfusion),
Cell Retention Techniques for Use in Continuous Operation in Suspended Cell Perfusion Processes,
Cell Retention Based on Size: Different Types of Filtration Techniques,
Separation Based on Body Force Difference,
Acoustic Devices,
Types of Cells and Modes of Growth,
Growth Phases of Cells,
The Cell and Its Viability in Bioreactors,
Shear Sensitivity,
Hydrodynamics,
Mixing in Bioreactors,
Gas Dispersion,
Importance of Gas Dispersion,
Effect of Dissolved Carbon Dioxide on Bioprocess Rate,
Factors That Affect Gas Dispersion,
Estimation of NCD,
Solid Suspension,
Two-Phase (Solid–Liquid) Systems,
Three-Phase (Gas–Liquid–Solid) Systems,
Mass Transfer,
Fractional Gas Holdup (εG),
Gas–Liquid Mass Transfer,
Liquid–Cell Mass Transfer,
Foaming in Cell Culture Systems: Effects on Hydrodynamics and Mass Transfer,
Heat Transfer in Stirred Bioreactors,
Worked Cell Culture Reactor Design Example,
Conventional Batch Stirred Reactor with Air Sparging for Microcarrier-Supported Cells: A Simple Design Methodology for Discerning the Rate-Controlling Step,
Reactor Using Membrane-Based Oxygen Transfer,
Heat Transfer Area Required,
Special Aspects of Stirred Bioreactor Design,
The Reactor Vessel,
Sterilizing System,
Measurement Probes,
Agitator Seals,
Gasket and O-Ring Materials,
Vent Gas System,
Cell Retention Systems in Perfusion Culture,
Concluding Remarks,
Nomenclature,
References,
Venturi Loop Reactor
Introduction,
Application Areas for the Venturi Loop Reactor,
Two Phase (Gas–Liquid Reactions),
Three-Phase (Gas–Liquid–Solid-Catalyzed) Reactions,
Advantages of the Venturi Loop Reactor: A Detailed Comparison,
Relatively Very High Mass Transfer Rates,
Lower Reaction Pressure,
Well-Mixed Liquid Phase,
Efficient Temperature Control,
Efficient Solid Suspension and Well-Mixed Solid (Catalyst) Phase,
Suitability for Dead-End System,
Excellent Draining/Cleaning Features,
Easy Scale-Up,
The Ejector-Based Liquid Jet Venturi Loop Reactor,
Operational Features,
Components and Their Functions,
The Ejector–Diffuser System and Its Components,
Hydrodynamics of Liquid Jet Ejector,
Flow Regimes,
Prediction of Rate of Gas Induction,
Design of Venturi Loop Reactor,
Mass Ratio of Secondary to Primary Fluid,
Gas Holdup,
Gas–Liquid Mass Transfer: Mass Transfer Coefficient (kLa) and Effective Interfacial Area (a),
Solid Suspension in Venturi Loop Reactor,
Solid–Liquid Mass Transfer,
Holding Vessel Size,
Recommended Overall Configuration,
Scale-Up of Venturi Loop Reactor,
Worked Examples for Design of Venturi Loop Reactor: Hydrogenation of Aniline to Cyclohexylamine,
Nomenclature,
References,
Gas-Inducing Reactors
ntroduction and Application Areas of Gas-Inducing Reactors,
Advantages,
Drawbacks,
Mechanism of Gas Induction,
Classification of Gas-Inducing Impellers,
1–1 Type Impellers,
1–2 and 2–2 Type Impellers,
Multiple-Impeller Systems Using 2–2 Type Impeller for Gas Induction,
Critical Speed for Gas Induction,
Rate of Gas Induction (QG),
Critical Speed for Gas Dispersion,
Critical Speed for Solid Suspension,
Operation of Gas-Inducing Reactor with Gas Sparging,
Solid–Liquid Mass Transfer Coefficient (KSL),
Worked Example: Design of Gas-Inducing System with Multiple Impellers for Hydrogenation of Aniline to Cyclohexylamine (Capacity: 25,000 Metric Tonnes per Year),
Geometrical Features of the Reactor/Impeller (Dimensions and Geometric Configuration as per Section 7A.10 and Figure 9.9, Respectively),
Basic Parameters,
Nomenclature,
References,
Two- and Three-Phase Sparged Reactors
Introduction,
Hydrodynamic Regimes in TPSR,
Slug Flow Regime,
Homogeneous Bubble Flow Regime,
Heterogeneous Churn-Turbulent Regime,
Transition from Homogeneous to Heterogeneous Regimes,
Gas Holdup,
Effect of Sparger,
Effect of Liquid Properties,
Effect of Operating Pressure,
Effect of Presence of Solids,
Solid–Liquid Mass Transfer Coefficient (KSL),
Effect of Gas Velocity on KSL,
Effect of Particle Diameter dP on KSL,
Effect of Column Diameter on KSL,
Correlation for KSL,
Gas–Liquid Mass Transfer Coefficient (kLa),
Axial Dispersion,
Comments on Scale-Up of TPSR/Bubble Columns,
Reactor Design Example for Fischer–Tropsch Synthesis Reactor,
ntroduction,
Physicochemical Properties,
Basis for Reactor Design, Material Balance, and Reactor Dimensions,
Calculation of Mass Transfer Parameters,
Estimation of Rates of Individual Steps and Determination of the Rate Controlling Step,
Sparger Design,
TPSR (Loop) with Internal Draft Tube (BCDT),
ntroduction,
Hydrodynamic Regimes in TPSRs with Internal Draft Tube,
Gas–Liquid Mass Transfer,
Solid Suspension,
Solid–Liquid Mass Transfer Coefficient (KSL),
Correlation for KSL,
Application of BCDT to Fischer–Tropsch Synthesis,
Application of BCDT to Oxidation of p-Xylene to Terephthalic Acid,
Nomenclature,
References,