Two-Phase Bubble Columns: A Comprehensive Review

Towards Tomography-Based Real-Time Control of Multiphase Flows: A Proof of Concept in Inline Fluid Separation

The performance of multiphase flow processes is often determined by the distribution of phases inside the equipment. However, controllers in the field are typically implemented based on flow variables, which are simpler to measure, but indirectly connected to performance (e.g., pressure). Tomography has been used in the study of the distribution of phases of multiphase flows for decades, but only recently, the temporal resolution of the technique was sufficient for real-time reconstructions of the flow. Due to the strong connection between the performance and distribution of phases, it is expected that the introduction of tomography to the real-time control of multiphase flows will lead to substantial improvements in the system performance in relation to the current controllers in the field. This paper uses a gas–liquid inline swirl separator to analyze the possibilities and limitations of tomography-based real-time control of multiphase flow processes. Experiments were performed in the separator using a wire-mesh sensor (WMS) and a high-speed camera to show that multiphase flows have two components in their dynamics: one intrinsic to its nonlinear physics, occurring independent of external process disturbances, and one due to process disturbances (e.g., changes in the flow rates of the installation). Moreover, it is shown that the intrinsic dynamics propagate from upstream to inside the separator and can be used in predictive and feedforward control strategies. In addition to the WMS experiments, a proportional–integral feedback controller based on electrical resistance tomography (ERT) was implemented in the separator, with successful results in relation to the control of the distribution of phases and impact on the performance of the process: the capture of gas was increased from 76% to 93% of the total gas with the tomography-based controller. The results obtained with the inline swirl separator are extended in the perspective of the tomography-based control of quasi-1D multiphase flows.

Modeling and Simulation of Photobioreactors with Computational Fluid Dynamics—A Comprehensive Review

Computational Fluid Dynamics (CFD) have been frequently applied to model the growth conditions in photobioreactors, which are affected in a complex way by multiple, interacting physical processes. We review common photobioreactor types and discuss the processes occurring therein as well as how these processes have been considered in previous CFD models. The analysis reveals that CFD models of photobioreactors do often not consider state-of-the-art modeling approaches. As a comprehensive photobioreactor model consists of several sub-models, we review the most relevant models for the simulation of fluid flows, light propagation, heat and mass transfer and growth kinetics as well as state-of-the-art models for turbulence and interphase forces, revealing their strength and deficiencies. In addition, we review the population balance equation, breakage and coalescence models and discretization methods since the predicted bubble size distribution critically depends on them. This comprehensive overview of the available models provides a unique toolbox for generating CFD models of photobioreactors. Directions future research should take are also discussed, mainly consisting of an extensive experimental validation of the single models for specific photobioreactor geometries, as well as more complete and sophisticated integrated models by virtue of the constant increase of the computational capacity.

Coupled Electrohydrodynamic and Thermocapillary Instability of Multi-Phase Flows Using an Incompressible Smoothed Particle Hydrodynamics Method

This paper concerns the study of coupled effects of electrohydrodynamic (EHD) and thermocapillary (TC) on the dynamic behaviour of a single liquid droplet. An incompressible Smoothed Particle Hydrodynamic (ISPH) multiphase model is used to simulate EHD-TC driven flows. The complex hydrodynamic interactions are modeled using the continuum surface force (CSF) method, in which the gradient of the interfacial tension and the Marangoni forces are calculated with an approximated error or 0.014% in the calculation of Marangoni force compared to the analytical solutions which is a significant improvement in comparison with previous SPH simulation studies, under the assumption that the thermocapillarity generates sufficiently large stress to allow droplet migration, while the electrohydrodynamic phenomena influences the droplet morphology depending on the electrical and thermal ratios of the droplet and the ambient fluid. This study shows that, when applying a vertical electric field and thermal gradient, the droplet starts to stretch horizontally towards a break-up condition at a high rate of electrical permitivity. The combined effect of thermal gradient and electric field tends to push further the droplet towards the break-up regime. When the thermal gradient and the electric field vector are orthogonal, results show that the droplet deformation would take place more slowly and the Marangoni forces cause the droplet to migrate, while the stretching in the direction of the electric field is not seen to be as strong as in the first case.

Unraveling the Contribution of Turbulence and Bubbles to Air-Water Gas Exchange in Running Waters

Quantifying air-water gas exchange is critical for estimating greenhouse gas fluxes and metabolism in aquatic ecosystems. In high-energy streams, the gas exchange rate k is poorly constrained, due to an incomplete understanding of turbulence and bubble contributions to k. We performed a flume experiment with air bubble additions to evaluate the combined effects of turbulence and bubbles on k for helium, argon, xenon, and methane. We created contrasting hydraulic conditions by varying channel slope, bed roughness, water discharge, and bubble flux. We found that k increased from 1-4 to 17-66 m d^-1 with increases in turbulence and bubble flux metrics. Mechanistic models that explicitly account for these metrics, as well as gas diffusivity and solubility, agreed well with the data and indicated that bubble-mediated gas exchange accounted for 64-93% of k. Bubble contributions increased with bubble flux but were independent of gas type, as bubbles did not equilibrate with the water. This was evident through modeled bubble life and equilibration times inferred from bubble size distributions obtained from underwater sound spectra. Sound spectral properties correlated well with turbulence and bubble flux metrics. Our results demonstrate that (a) mechanistic models can be applied to separate free surface- and bubble-mediated gas exchange in running waters, (b) bubble life and equilibration times are critical for accurate scaling of k between different gases, and (c) ambient sound spectra can be used to approximate contributions of turbulence and bubbles.

Reactor Designs and Configurations for Biological and Bioelectrochemical C1 Gas Conversion: A Review

Microbial C1 gas conversion technologies have developed into a potentially promising technology for converting waste gases (CO₂, CO) into chemicals, fuels, and other materials. However, the mass transfer constraint of these poorly soluble substrates to microorganisms is an important challenge to maximize the efficiencies of the processes. These technologies have attracted significant scientific interest in recent years, and many reactor designs have been explored. Syngas fermentation and hydrogenotrophic methanation use molecular hydrogen as an electron donor. Furthermore, the sequestration of CO₂ and the generation of valuable chemicals through the application of a biocathode in bioelectrochemical cells have been evaluated for their great potential to contribute to sustainability. Through a process termed microbial chain elongation, the product portfolio from C1 gas conversion may be expanded further by carefully driving microorganisms to perform acetogenesis, solventogenesis, and reverse β-oxidation. The purpose of this review is to provide an overview of the various kinds of bioreactors that are employed in these microbial C1 conversion processes.

Small-Scale Phenomena in Reactive Bubbly Flows: Experiments, Numerical Modeling, and Applications

Improving the yield and selectivity of chemical reactions is one of the challenging tasks in paving the way for a more sustainable and climate-friendly economy. For the industrially highly relevant gas-liquid reactions, this can be achieved by tailoring the timescales of mixing to the requirements of the reaction. Although this has long been known for idealized reactors and time- and space-averaged processes, considerable progress has been made recently on the influence of local mixing processes. This progress has become possible through joint research between chemists, mathematicians, and engineers. We present the reaction systems with adjustable kinetics that have been developed, which are easy to handle and analyze. We show examples of how the selectivity of competitive-consecutive reactions can be controlled via local bubble wake structures. This is demonstrated for Taylor bubbles and bubbly flows under technical conditions. Highly resolvednumerical simulations confirm the importance of the bubble wake structure for the performance of a particular chemical reaction and indicate tremendous potential for future process improvements.

A Review of Bubble Dynamics in Liquid Metals

Gas bubbles are of major importance in most metallurgical processes. They promote chemical reactions, homogenize the melt, or float inclusions. Thus, their dynamics are of crucial interest for the optimization of metallurgical processes. In this work, the state of knowledge of bubble dynamics at the bubble scale in liquid metals is reviewed. Measurement methods, with emphasis on liquid metals, are presented, and difficulties and shortcomings are analyzed. The bubble formation mechanism at nozzles and purging plugs is discussed. The uncertainty regarding the prediction of the bubble size distribution in real processes is demonstrated using the example of the steel casting ladle. Finally, the state of knowledge on bubble deformation and interfacial forces is summarized and the scalability of existing correlations to liquid metals is critically discussed. It is shown that the dynamics of bubbles, especially in liquid metals, are far from understood. While the drag force can be predicted reasonably well, there are large uncertainties regarding the bubble size distribution, deformation, and lift force. In particular, the influence of contaminants, which cannot yet be quantified in real processes, complicates the discussion and the comparability of experimental measurements. Further open questions are discussed and possible solutions are proposed.

Design, Commissioning, and Performance Assessment of a Lab-Scale Bubble Column Reactor for Photosynthetic Biogas Upgrading with Spirulina platensis

The two-step bubble column-photobioreactor photosynthetic biogas upgrading system can enable simultaneous production of biomethane and value-added products from microalgae. However, due to the influence of a large number of variables, including downstream processes and the presence of microalgae, no unanimity has been reached regarding the performance of bubble column reactors in photosynthetic biogas upgrading. To investigate this further, the present work documents in detail, the design and commissioning of a lab-scale bubble column reactor capable of treating up to 16.3 L/h of biogas while being scalable. The performance of the bubble column was assessed at a pH of 9.35 with different algal densities of Spirulina platensis at 20 °C in the presence of light (3–5 klux or 40.5–67.5 μmol m^–2 s^–1). A liquid/gas flow (L/G) ratio of 0.5 allowed consistent CO₂ removal of over 98% irrespective of the algal density or its photosynthetic activity. For lower concentrations of algae, the volumetric O₂ concentration in the upgraded biomethane varied between 0.05 and 0.52%, thus providing grid quality biomethane. However, for higher algal concentrations, increased oxygen content in the upgraded biomethane due to both enhanced O₂ stripping and the photosynthetic activity of the microalgae as well as clogging and foaming posed severe operational challenges.

Tuning the Morphology of Protein-Inorganic Calcium-Phosphate Supraparticles via Directed Assembly

Understanding the phenomena that govern complex interfacial and directed assemblies is essential for both control and scale-up of particle syntheses. The present work describes an effort to understand, control, and tune the formation of protein-inorganic calcium-phosphate supraparticles that are produced at an oscillating air-water interface created by end-over-end rotation of the synthesis solution. Supraparticles were synthesized under an array of different conditions that varied reagent concentration, the presence of additives, tube size, and rotational speed. Paired with a fluid mechanics model of the end-over-end rotation and dimensional analysis, the sensitivity of the synthesis to physicochemical and mechanical parameters was determined. Surface tension and bubble formation were found to be important criteria for changing the size distribution of supraparticles. Thresholds for the values of the Froude, Iribarren, and rotational Reynolds numbers were identified for narrowing particle size distribution. These results both guide the specific protein-inorganic supraparticle synthesis described here and inform future manipulation and scale-up of other complex interfacial colloidal assemblies.

Determination of a Bubble Drag Coefficient during the Formation of Single Gas Bubble in Upward Coflowing Liquid

Bubble flow is present in many processes that are the subject of chemical engineering research. Many correlations for determination of the equivalent bubble diameter can be found in the scientific literature. However, there are only few describing the formation of gas bubbles in flowing liquid. Such a phenomenon occurs for instance in airlift apparatuses. Liquid flowing around the gas bubble creates a hydraulic drag force that leads to reduction of the formed bubble diameter. Usually the value of the hydraulic drag coefficient, cD, for bubble formation in the flowing liquid is assumed to be equal to the drag coefficient for bubbles rising in the stagnant liquid, which is far from the reality. Therefore, in this study, to determine the value of the drag coefficient of bubbles forming in flowing liquid, the diameter of the bubbles formed at different liquid velocity was measured using the shadowgraphy method. Using the balance of forces affecting the bubble formed in the coflowing liquid, the hydraulic drag coefficient was determined. The obtained values of the drag coefficient differed significantly from those calculated using the correlation for gas bubble rising in stagnant liquid. The proposed correlation allowed the determination of the diameter of the gas bubble with satisfactory accuracy.

A Transport-Phenomena Approach to Model Hydrodynamic Cavitation of Organic Pollutants

Hydrodynamic cavitation (HC) has been extensively studied for the Advanced Oxidation of organic compounds in wastewaters since it physically produces an oxidative environment at ambient conditions. This process is simple and economical since it can be realized through a properly designed restriction in a pipeline, even in retrofit solutions. Several experimental works individuated similar values of the optimal operating conditions, especially with regard to the inlet pressure. Up to now, the available modeling works rely on a single-bubble dynamics (SBD) approach and do not consider the actual process configuration and pollutant transport in proximity to the oxidizing environment. This work describes different experimental results (from this research group and others) and applies a novel mathematical model based on a transport-phenomena approach, able to directly simulate the effect of HC on the pollutant degradation. The novel proposed model is able to reproduce well a large number of experimental data obtained in different conditions, with different apparatus and different molecules, and allows to interconnect both SBD, fluid-dynamics, and physio-chemical variables in order to deeply study the interaction between the transport of pollutants and the reactive environment. This paper includes collection and discussion of several experimental results with the related main process parameters, description of the novel model and validation against the cited experimental results (to explain the effect of the operating pressure), sensitivity analysis, and the performance limit of the HC with the proposed modeling approach.

Twente mass and heat transfer water tunnel: Temperature controlled turbulent multiphase channel flow with heat and mass transfer

A new vertical water tunnel with global temperature control and the possibility for bubble and local heat and mass injection has been designed and constructed. The new facility offers the possibility to accurately study heat and mass transfer in turbulent multiphase flow (gas volume fraction up to 8%) with a Reynolds-number range from 1.5 × 10⁴ to 3 × 10⁵ in the case of water at room temperature. The tunnel is made of high-grade stainless steel permitting the use of salt solutions in excess of 15% mass fraction. The tunnel has a volume of 300 l. The tunnel has three interchangeable measurement sections of 1 m height but with different cross sections (0.3 × 0.04 m², 0.3 × 0.06 m², and 0.3 × 0.08 m²). The glass vertical measurement sections allow for optical access to the flow, enabling techniques such as laser Doppler anemometry, particle image velocimetry, particle tracking velocimetry, and laser-induced fluorescent imaging. Local sensors can be introduced from the top and can be traversed using a built-in traverse system, allowing, for example, local temperature, hot-wire, or local phase measurements. Combined with simultaneous velocity measurements, the local heat flux in single phase and two phase turbulent flows can thus be studied quantitatively and precisely.