Hydrodynamics of gas-liquid flow in micropacked beds: Pressure drop, liquid holdup, and two-phase model

Bayesian based reaction optimization for complex continuous gas–liquid–solid reactions

In recent years, self-optimization strategies have been gradually utilized for the determination of optimal reaction conditions owing to their high convenience and independence from researchers' experience.

Copper/TEMPO-catalyzed continuous aerobic alcohol oxidation in a micro-packed bed reactor

A micro-packed bed reactor has been developed to demonstrate aerobic oxidation of alcohols to aldehydes, utilizing green oxidant O2 and effective Cu/TEMPO-catalyzed system.

Continuous-flow reactor setup for operando x-ray absorption spectroscopy of high pressure heterogeneous liquid-solid catalytic processes

A continuous-flow reactor and a continuous-flow setup compatible with operando x-ray absorption spectroscopy (XAS) were designed for safely studying liquid-phase reactions on solid high atomic number transition metal catalysts (e.g., Au, Pd, and Pt) under pressures up to 100 bars with temperatures up to 100 °C. The reactor has a stainless-steel body, 2 mm thick polyether ether ketone (PEEK) x-ray windows, and a low internal volume of 0.31 ml. The rectangular chamber (6 × 5 × 1 mm³) between the PEEK x-ray windows allows us to perform XAS studies of packed beds or monoliths in the transmission mode at any position in the cell over a length of 60 mm. A 146° wide-angle beam access also allows recording complementary x-ray fluorescence or x-ray diffraction signals. The setup was engineered to continuously feed a single-phase liquid flow saturated with one or more gaseous reactants to the liquid-solid XAS reactor containing no free gas phase for enhanced process safety and sample homogeneity. The proof of concept for the continuous-flow XAS cell and high-pressure setup was provided by operando XAS measurements during the direct synthesis of hydrogen peroxide at room temperature and 40 bars using a 35 ± 5 mg catalyst (1 wt. % Pd/TiO₂) and inline near-infrared spectroscopy. The experiments prove that the system is well suited to follow the reaction in the liquid phase while recording high-quality XAS data, paving the way for detailed studies on the catalyst structure and structure-activity relationships.

Study of Liquid-Solid Mass Transfer and Hydrodynamics in Micropacked Bed with Gas-Liquid Flow

The volumetric liquid–solid (L-S) mass transfer coefficient under gas–liquid (G-L) two-phase flow in a silicon-chip-based micropacked bed reactor (MPBR) was studied using the copper dissolution method and was related to the reactor hydrodynamic behavior. Using a high-speed camera and a robust computational image analysis method that selectively analyzed the bed voidage around the copper particles, the observed hydrodynamics were directly related to the L-S mass transfer rates in the MPBR. This hydrodynamic study revealed different pulsing structures inside the packed copper bed depending on the flow patterns established preceding the packed bed upon increasing gas velocity. A “liquid-dominated slug” flow regime was associated with an upstream slug flow feed. A “sparse slug” flow regime developed with an upstream slug-annular flow feed. At higher gas velocity, a “gas continuous with pulsing” regime developed with an annular flow feed, which had similar features to the pulsing flow in macroscale packed beds, but it was sensitive and easily destabilized by disturbances from upstream or downstream pressure fluctuations. The volumetric L-S mass transfer coefficient decreased with increasing gas velocity under the liquid-dominated slug flow regime and became rather less affected under the sparse slug flow regime. By resolving the transition from the liquid-dominated slug flow to the sparse slug flow and capturing the onset of the gas-continuous with pulsing regime, we gained new insights into the hydrodynamic effects of G-L flows on the L-S mass transfer rates in a MPBR.

Rapid degradation of refractory organic pollutants by continuous ozonation in a micro-packed bed reactor

Recently microreactor technology attracts attention due to the excellent multiphase mixing and enhanced mass transfer. Herein, a continuous ozonation system based on a micro-packed bed reactor (μPBR) was used to improve the dissolution rate of ozone and achieved a rapid and efficient degradation of refractory organic pollutants. The effects of liquid flow rate, gas flow rate, initial pH, initial O₃ concentration and initial phenol concentration on the phenol and chemical oxygen demand (COD) removal efficiencies were also investigated. Experimental results showed that phenol and COD removal efficiencies under optimal conditions achieved 100.0% and 86.4%, respectively. Compared with large-scale reactors, the apparent reaction rate constant in μPBR increased by 1-2 orders of magnitude. In addition, some typical organic pollutants (including phenols, antibiotics and dyes) were treated by ozonation in μPBR. The removal efficiencies of these organic pollutants and COD achieved 100.0% and 70.2%-80.5% within 71 s, respectively. In this continuous treatment system, 100% of the unreacted ozone was converted to oxygen, which promoted the healthy development of aquatic ecosystems. Thus, this continuous system based on μPBR is a promising method in rapid and efficient treating refractory organic pollutants.

Enabling low power acoustics for capillary sonoreactors

Capillary reactors demonstrate outstanding potential for on-demand flow chemistry applications. However, non-uniform distribution of multiphase flows, poor solid handling, and the risk of clogging limit their usability for continuous manufacturing. While ultrasonic irradiation has been traditionally applied to address some of these limitations, their acoustic efficiency, uniformity and scalability to larger reactor systems are often disregarded. In this work, high-speed microscopic imaging reveals how cavitation-free ultrasound can unclog and prevent the blockage of capillary reactors. Modeling techniques are then adapted from traditional acoustic designs and applied to simulate and prototype sonoreactors with wider and more uniform sonication areas. Blade-, block- and cylindrical shape sonotrodes are optimized to accommodate longer capillary lengths in sonoreactors resonating at 28 kHz. Finally, a novel helicoidal capillary sonoreactor is proposed to potentially deal with a high concentration of solid particles in miniaturized flow chemistry. The acoustic designs and first principle rationalization presented here offer a transformative step forward in the scale-up of efficient capillary sonoreactors.