Jet loop reactors as a versatile reactor set up - Intensifying catalytic reactions: A review

A novel physical-biochemical treatment of refinery wastewater

As of 2022, China has achieved a crude oil processing capacity of 918 million tons, leading to a notable escalation in the production of refinery wastewater. The composition of refinery wastewater is intricate and diverse, posing a substantial challenge to its treatment. In order to facilitate appropriate discharge or reuse, an exhaustive separation process is imperative for refinery wastewater. Conventional pre-treatment processes typically employ inclined plate separators and dissolved air flotation (DAF) for the removal of oil and suspended solids (SS), while sequencing batch reactor (SBR), oxidation ditch, or biological aerated filter (BAF) are employed for the biological treatment process. However, these approaches encounter challenges such as a large spatial footprint, suboptimal treatment efficiency, and high energy consumption. In response to these challenges, this study introduces a novel integrated apparatus consisting of a high-efficiency oil remover (HEOR), coalescence oil remover (COR), and an airlift-enhanced loop bioreactor (AELR). A pilot-scale test was conducted to evaluate the performance of this integrated system in practical field applications. The pilot-scale tests reveal that, without the addition of chemical agents, the petroleum removal efficiency of "HEOR + COR" system was 1.2 times that of DAF. Compared with the SBR system, AELR's volume loading was increased by 1.56 times. The effluent quality achieved in the pilot-scale tests attained parity with that the original process. The "HEOR + COR + AELR" system exhibited energy and carbon emissions reduction of 28% and 30% compared to the "DAF + SBR" system, respectively. Therefore, the operating costs was reduced by approximate 1 Chinese Yuan (CNY) per ton of treated water. This technological advancement serves as a valuable reference for the implementation of low-carbon treatment of refinery wastewater.

Optimizing reaction conditions for the light-driven hydrogen evolution in a loop photoreactor

Photocatalytic hydrogen production from water is a promising way to fulfill energy demands and attain carbon emission reduction goals effectively. In this study, a loop photoreactor with a total volume of around 500 mL is presented for the photocatalytic hydrogen evolution using a Pt-loaded polymeric carbon nitride photocatalyst under 365 nm irradiation in the presence of sacrificial reducing agents. The fluid flow pattern of the developed photoreactor was characterized experimentally and the photon flux incident to the loop photoreactor was measured by chemical actinometry. The system displayed exceptional stability, with operation sustained over 70 hours. A design of experiment (DOE) analysis was used to systematically investigate the influence of key parameters - photon flux, photocatalyst loading, stirring speed, and inert gas flow rate - on the hydrogen generation rate. Linear relationships were found between hydrogen evolution rate and photon flux as well as inert gas flow rate. Photocatalyst loading and stirring speed also showed linear correlations, but could not be correctly described by DOE analysis. Instead, linear single parameter correlations could be applied. Notably, the loop photoreactor demonstrated an external photon efficiency up to 17 times higher than reported in literature studies, while scaling the reactor size by a factor of 10.

Model-Based Investigation of the Interaction of Gas-Consuming Reactions and Internal Circulation Flow within Jet Loop Reactors

Jet loop reactors are standard multiphase reactors used in chemical, biological and environmental processes. The strong liquid jet provided by a nozzle enforces both internal circulation of liquid and gas as well as entrainment and dispersion of the gas phase. We present a one-dimensional compartment model based on a momentum balance that describes the internal circulation of gas and liquid phase in the jet loop reactor. This model considers the influence of local variations of the gas volume fraction on the internal circulation. These local variations can be caused by coalescence of gas bubbles, additional gas-feeding points and gas consumption or production. In this work, we applied the model to study the influence of a gas-consuming reaction on the internal circulation. In a comprehensive sensitivity analysis, the interaction of different parameters such as rate of reaction, power input through the nozzle, gas holdup, reactor geometry, and circulation rate were investigated. The results show that gas consumption can have a significant impact on internal circulation. Industrially relevant operating conditions have even been found where the internal circulation comes to a complete standstill.

Investigation on gas induction of liquid–gas ejector in jet loop reactor

Liquid–gas ejector as a key component of jet loop reactor (JLR), plays an important role in the continuous production of gas–liquid mixing reaction. In this paper, a formula for estimating the gas induction of the ejector is presented. The effects of nozzle radius and mixing length on gas induction of liquid–gas ejector for gas–liquid mixing are simulated, and the formula is verified. Focusing on the efficiency and gas induction, the geometrical parameters are analyzed for the same cases, so that the performance of the ejector can be thoroughly understood. The results show that the optimum mixing section length to diameter ratio (LDR) is about 5–7, and the decrease of nozzle outlet radius can increase the gas induction, which provides a reference for the evaluation of gas induction for liquid–gas ejector and has crucial guiding significance for the design of nozzle and mixing section of liquid–gas ejector in industry.

Green Process Design for Reductive Hydroformylation of Renewable Olefin Cuts for Drop-In Diesel Fuels

CO2 -neutral fuels are a way to cleaner and more sustainable mobility. Utilization of bio-syngas via Fischer-Tropsch (FT) synthesis represents an interesting route for the production of tailormade biofuels. Recent developments in FT catalyst research led to olefin-enriched products, enabling the synthesis of alcohol-enriched fuels by reductive hydroformylation of the C=C bond. Several alcohols have already proven to be suitable fuel additives with favorable combustion behavior. Here, a hydroformylation-hydrogenation sequence of FT-olefin-paraffin mixtures was investigated as a potential route to alcohols. A liquid-liquid biphasic system with a rhodium/3,3',3''-phosphanetriyltris(benzenesulfonic acid) trisodium salt (TPPTS) catalyst system was chosen for effective catalyst recycling. After optimizing reaction conditions with a model substrate consisting of 1-octene and n-heptane the conversion of an actual olefin-containing C5 -C10  FT product fraction to alcohols in continuously operated processes for 37 h was achieved with a total turnover number of 23679.

Another Critical Look at Three-Phase Catalysis

Three-phase catalysis, for example, hydrogenation, is a special branch of chemical reactions involving a hydrogen reactant (gas) and a solvent (liquid) in the presence of a metal porous catalyst (solid) to produce a liquid product. Currently, many reactors are being used for three-phase catalysis from packed bed to slurry vessel; the uniqueness for this type of reaction in countless processes is the requirement of transferring gas into liquid, as yet there is not a unified system of quantifying and comparing reactor performances. This article reviews current methodologies in carrying out such heterogeneous catalysis in different reactors and focuses on how to enhance reactor performance from gas transfer perspectives. This article also suggests that the mass transfer rate over energy dissipation may represent a fairer method for comparison of reactor performance accounting for different types/designs of reactors and catalyst structures as well as operating conditions.

Design of a Novel Membrane Draft Tube Jet Loop Reactor (MDJLR) and Treatment of Slaughterhouse Wastewater

The most important obstacle to the widespread use of membrane bioreactors (MBRs) is membrane fouling. In this study, a high-efficiency compact MBR was developed. Therefore, the draft tube of the jet loop reactor (JLB) was planned for use as a membrane module. The high-velocity jet streams, which are present according to the nature of the JLBs, provide high crossflow (cut-off force) on the membrane surface. Thus, the produced membrane module is operated in submerged membrane mode. This enhanced JLB modification is named the membrane draft tube jet loop reactor (MDJLR). This new system has a KLa value of 139 h-1 (at E/V of 2.24 kW m-3). In the next stage, treatment of slaughterhouse wastewater with the MDJLR was carried out. Under the 5.5 kg COD m-3 d-1 loading rate, efficiencies over 97% were achieved. The system operated continuously for 50 days without membrane backwashing or cleaning. During this period, fluxes of 3 L m-2·h-1 were approximately obtained at operating conditions of 850 mg L-1 MLSS (mixed liquor suspended solids) concentration, 1 bar suction pressure (∆P), and 3000 L h-1 circulation rate. This developed MDJLR will make jet loop membrane bioreactors (JLMBRs) and MBRs more compact and improve their performance.

Optimization of Reaction Selectivity Using CFD-Based Compartmental Modeling and Surrogate-Based Optimization

Mixing is considered as a critical process parameter (CPP) during process development due to its significant influence on reaction selectivity and process safety. Nevertheless, mixing issues are difficult to identify and solve owing to their complexity and dependence on knowledge of kinetics and hydrodynamics. In this paper, we proposed an optimization methodology using Computational Fluid Dynamics (CFD) based compartmental modelling to improve mixing and reaction selectivity. More importantly, we have demonstrated that through the implementation of surrogate-based optimization, the proposed methodology can be used as a computationally non-intensive way for rapid process development of reaction unit operations. For illustration purpose, reaction selectivity of a process with Bourne competitive reaction network is discussed. Results demonstrate that we can improve reaction selectivity by dynamically controlling rates and locations of feeding in the reactor. The proposed methodology incorporates mechanistic understanding of the reaction kinetics together with an efficient optimization algorithm to determine the optimal process operation and thus can serve as a tool for quality-by-design (QbD) during product development stage.

Impact of nozzle operation on mass transfer in jet aerated loop reactors. Characterization and comparison to an aerated stirred tank reactor

The impact of mass transfer on productivity can become a crucial aspect in the fermentative production of bulk chemicals. For highly aerobic bioprocesses the oxygen transfer rate (OTR) and productivity are coupled. The achievable space time yields can often be correlated to the mass transfer performance of the respective bioreactor. The oxygen mass transfer capability of a jet aerated loop reactor is discussed in terms of the volumetric oxygen mass transfer coefficient k_La [h^-1] and the energetic oxygen transfer efficiency E [kgO₂ kW^-1 h^-1]. The jet aerated loop reactor (JLR) is compared to the frequently deployed aerated stirred tank reactor. In jet aerated reactors high local power densities in the mixing zone allow higher mass transfer rates, compared to aerated stirred tank reactors. When both reactors are operated at identical volumetric power input and aeration rates, local k_La values up to 1.5 times higher are possible with the JLR. High dispersion efficiencies in the JLR can be maintained even if the nozzle is supplied with pressurized gas. For increased oxygen demands (above 120 mmol L^-1 h^-1) improved energetic oxygen transfer efficiencies of up to 100 % were found for a JLR compared to an aerated stirred tank reactor operating with Rushton turbines.

Jet aeration as alternative to overcome mass transfer limitation of stirred bioreactors

In industrial biotechnology increasing reactor volumes have the potential to reduce production costs. Whenever the achievable space time yield is determined by the mass transfer performance of the reactor, energy efficiency plays an important role to meet the requirements regarding low investment and operating costs. Based on theoretical calculations, compared to bubble column, airlift reactor, and aerated stirred tank, the jet loop reactor shows the potential for an enhanced energetic efficiency at high mass transfer rates. Interestingly, its technical application in standard biotechnological production processes has not yet been realized. Compared to a stirred tank reactor powered by Rushton turbines, maximum oxygen transfer rates about 200% higher were achieved in a jet loop reactor at identical power input in a fed batch fermentation process. Moreover, a model-based analysis of yield coefficients and growth kinetics showed that E. coli can be cultivated in jet loop reactors without significant differences in biomass growth. Based on an aerobic fermentation process, the assessment of energetic oxygen transfer efficiency [kgO₂ kW^-1 h^-1] for a jet loop reactor yielded an improvement of almost 100%. The jet loop reactor could be operated at mass transfer rates 67% higher compared to a stirred tank. Thus, an increase of 40% in maximum space time yield [kg m^-3 h^-1] could be observed.