Use of computational fluid dynamics simulations for design of a pretreatment screw conveyor reactor

Computational fluid dynamics simulations were employed to compare performance of various designs of a pretreatment screw conveyor reactor. The reactor consisted of a vertical screw used to create cross flow between the upward conveying solids and the downward flow of acid. Simulations were performed with the original screw design and a modified design in which the upper flights of the screw were removed. Results of the simulations show visually that the modified design provided favorable plug flow behavior within the reactor. Pressure drop across the length of the reactor without the upper screws in place was predicted by the simulations to be 5 vs 40 kPa for the original design.     

Computational fluid dynamics simulation and redesign of a screw conveyor reactor

National Renewable Energy Laboratory (NREL) designed a shrinking-bed reactor to maintain a constant bulk packing density of cellulosic biomass. The high solid-to-liquid ratio in the pretreatment process allows a high sugar yield and avoids the need to flush large volumes of solution through the reactor. To scale up the shrinking-bed reactor, NREL investigated a pilot-scale screw conveyor reactor in which an interrupted flight between screws was employed to mimic the “shrinking-bed” effect. In the experiments with the screw conveyor reactor, overmixing and uneven flow occurred. These phenomena produce negative effects on biomass hydrolysis. The flow behavior inside the reactor was analyzed to allow redesign of the screw to achieve adequate mixing and even flow. In the present study, computational fluid dynamics (CFD) was utilized to simulate the fluid flow in the porous media, and a new screw design was proposed. CFD analysis performed on the redesigned reactor indicated that an even flow pattern was achieved.     

On-line desalting and carbohydrate analysis for immobilized enzyme hydrolysis of waste cellulosic biomass by column-switching high-performance liquid chromatography

An innovative green column-switching high-performance liquid chromatographic (HPLC) technique was developed by coupling traditional and Pb²⁺ ion-exclusion columns to study enzyme hydrolysis components of waste cellulosic biomass. Pure water was used as the mobile phase to separate neutral polar analytes in high salt content solution. The column-switching HPLC-RI was connected on-line to the immobilized enzyme reactor for successive on-line desalting and simultaneous analysis of six carbohydrates (cellobiose, glucose, xylose, galactose, mannose, and arabinose) in the hydrolysate of waste paper and waste tree branch by incorporating the heart-cut and the elution-time-difference techniques. Six internal standard calibration curves in the linear concentration range of 0–2000 μg mL⁻¹ were prepared. Xylitol was used as the internal standard to give excellent linear correlation coefficients (0.9984–0.9999). The limits of detection and quantification for cellobiose, glucose, xylose, galactose, mannose, and arabinose varied between 0.12–4.88 and 0.40–16.3 μg mL⁻¹, respectively, with an accuracy of 90–102% and a precision of 0.1–7.8%. Cellulose and hemicellulose contents were higher in waste paper than in waste tree branch.     

Mathematical modeling of flow and kinetics in a reactor for dilute-acid hydrolysis of cellulose particles

Amathematical model to simulate the dilute-acid hydrolysis process of cellulose particles is presented. In this model, the mass is treated as a mixture of different components. A test case is considered for which transport equations for components are developed and solved together with the momentum equation for the fluid flow. To solve the model equations, a commercially available flow solver was used. All input data were taken from previously published works. For the small static mixer considered as test geometry, the result, in terms of the conversion of the cellulose particles, was reasonable. With input parameters that are relevant to a plant-size reactor, the model can be used to predict the conversion of both cellulose and hemicellulose particles.     

Continuous fast pyrolysis of biomass at high temperature in a fluidized bed reactor

In order to perform biomass pyrolysis a continuous fluidized bed reactor (bench scale unit) has been assembled. The influence of experimental conditions such as heating-up time and optimum particle diameter is presented. By feeding the biomass (almond shells) directly into the bubbling bed, pyrolysis has been performed at temperatures ranging from 730° to 930°C at constant feed rate (44 g/h). Remarkable increase of H₂ in the product gas is observed when steam rather than an inert carrier such as nitrogen is used thus confirming the potential of this approach.The support of ENEA (Italian Agency for Renewable Energies) is gratefully acknowledged.     

Modeling of a continuous pretreatment reactor using computational fluid dynamics

Computational fluid dynamic simulations are employed to predict flow characteristics in a continuous auger driven reactor designed for the dilure acid pretreatment of biomass. Slurry containing a high concentration of biomass solids exhibits a high viscosity, which poses unique mixing issues within the reactor. The viscosity increases significantly with a small increase in solids concentration and also varies with temperature. A well-mixed slurry is desirable to evenly distribute acid on biomass, prevent buildup on the walls of the reactor, and provides an uniform final product. Simulations provide flow patterns obtained over a wide range of viscosities and pressure distributions, which may affect reaction rates. Results provide a tool for analyzing sources of inconsistencies in product quality and insight into future design and operating parameters.     

Impact of fluid velocity on hot water only pretreatment of corn stover in a flowthrough reactor

Flowthrough pretreatment with hot water only offers many promising features for advanced pretreatment of biomass, and a better understanding of the mechanisms responsible for flowthrough behavior could allow researchers to capitalize on key attributes while overcoming limitations. In this study, the effect of fluid velocity on the fate of total mass, hemicellulose, and lignin was evaluated for hot water only pretreatment of corn stover in tubular flow through reactors. Increasing fluid velocity significantly accelerated solubilization of total mass, hemicellulose, and lignin at early times. For example, when fluid velocity was increased from 2.8 to 10.7 cm/min, xylan removal increased from 60 to 82% for hot water only pretreatment of corn stover at 200°C after 8 min. At the same time, lignin removal increased from 30 to 46%. Dissolved hemicellulose was almost all in oligomeric form, and solubilization of hemicellulose was always accompanied by lignin release. The increase in removal of xylan and lignin with velocity, especially in the early reaction stage, suggests that chemical reaction is not the only factor controlling hemicellulose hydrolysis and that mass transfer and other physical effects may also play an important trole in hemicellulose and lignin degradation and removal.     

CaO伴随生物质热裂解制油同时脱氧的小型流化床实验研究

在小型流化床反应器中,对CaO伴随生物质快速热裂解制油过程中的直接脱氧效果进行了研究。当反应温度为520℃、载气流量8000L/h时,在纯白松粉末和CaO伴随条件下分别制出了生物油样品。实验结果表明,当采用纯白松与CaO/白松质量比分别为1、2、4时,生物油样品中有机组分的含氧量依次为39.38%、39.15%、39.04%和32.29%;在CaO/白松质量比为4时,生物油有机组分含氧量的下降幅度达18.0%（相对变化）。GC-MS分析结果表明,CaO加入后左旋葡聚糖和甲酸、乙酸等高含氧量物质相对含量明显下降,证实了CaO伴随生物质热裂解过程中“富氧中间体”固氧路径的存在;与此同时,糠醛类等主要来源于脱水反应的产物相对含量上升,说明CaO的加入也促进了脱水反应的发生。     

Heat transfer considerations in design of a batch tube reactor for biomass hydrolysis

Biologic conversion of inexpensive and abundant sources of cellulosic biomass offers a low-cost route to production of fuels and commodity chemicals that can provide unparalleled environmental, economic, and strategic benefits. However, low-cost, high-yiel technologies are needed to recover sugars from the hemicellulose fraction of biomass and to prepare the remaining cellulose fraction for subsequent hydrolysis. Uncatalyzed hemicellulose hydrolysis in flow-through systems offers a number of important advantages for removal of hemicellulose sugars, and it is believed that oligomers could play an important role in explaining why the performance of flow-through systems differs from uncatalyzed steam explosion approaches. Thus, an effort is under way to study oligomer formation kinetics, and a small batch reactor is being applied to capture these important intermediates in a closed system that facilitates material balance closure for varying reaction conditions. In this article, heat transfer for batch tubes is analyzed to derive temperature profiles for different tube diameters and assess the impact on xylan conversion. It was found that the tube diameter must be <0.5 in, for xylan hydrolysis to follow the kinetics expected for a uniform temperature system at typical operating conditions.     

Experimental and CFD Study of a Vertically Stirred Tubular Reactor Designed for Suspension Polymerization Reactions

A vertically stirred tubular reactor is designed and studied in this work to perform the styrene batch suspension polymerization. Computational fluid dynamic techniques are applied to acquire information regarding the heat transfer and fluid flow behavior along the reactor. The simulated findings are used to support the experimental results (particle size distribution—PSD) obtained by varying the stirring system configuration, stabilizing agent concentration, and system holdup (styrene/water ratio v/v). According to the results, an efficient temperature control is attained due to the tubular geometry of the equipment. In addition, the PSD broadens by increasing the size of the shaft and the number of impellers installed along the reactor. An evaluation of the particle sedimentation throughout the reaction demonstrates that the PSD and the stirring rate play an important role in the sedimentation kinetics. Such findings demonstrate the potential of the proposed reactor to be explored in order to perform suspension polymerizations semicontinuously or continuously by applying suitable operation strategies.

     

Shrinking-bed model for percolation process applied to dilute-acid pretreatment/hydrolysis of cellulosic biomass

For many lignocellulosic substrates, hemicellulose is biphasic upon dilute-acid hydrolysis, which led to a modified percolation process employing simulated two-stage reverse-flow. This process has been proven to attain substantially higher sugar yields and concentrations over the conventional single-stage percolation process. The dilute-acid pretreatment of biomass solubilizes the hemicellulose fraction in the solid biomass, leaving less solid biomass in the reactor and reducing the bed. Therefore, a bed-shrinking mathematic kinetic model was developed to describe the two-stage reverse-flow reactor operated for hydrolyzing biphasic substrates, including hemicellulose, in corn cob/stover mixture (CCSM). The simulation indicates that the shrinking-bed operation increases the sugar yield by about 5%, compared to the nonshrinking bed operation in which 1 reactor volume of liquid passes through the reactor (i.e.,t = 1.0). A simulated optimal run further reveals that the fast portion of hemicellulose is almost completely hydrolyzed in the first stage, and the slow portion of hemicellulose is hydrolyzed in the second stage. Under optimal conditions, the bed shrank 27% (a near-maximum value), and a sugar yield over 95% was attained.     

Depolymerization of xylan-derived products in an enzymatic membrane reactor

Rice husks were subjected to aqueous processing to obtain liquors containing xylan-derived products, which were assayed for composition. Liquors were diafiltered using 1 kDa ceramic membrane for purification purposes, and the retentate was concentrated using the same membrane. The molecular weight distribution of xylan-derived products in concentrated liquors was assayed by gel permeation chromatography. In order to achieve the one-step conversion of soluble, high molecular weight xylan-derived products into low molecular weight arabino-xylooligosaccharides (AXOS) and the recovery of low molecular weight AXOS, concentrated liquors were treated in a continuous enzymatic membrane reactor (EMR) with a commercial endoxylanase (Shearzyme 2X). Two operational modes were studied: in the first one, both enzymatic reaction and membrane operation began at the same time, whereas in the second case, permeation started when the reaction achieved a given conversion. Both operational modes are compared in terms of productivity.     

Molybdenum Disulphide Precipitation in Jet Reactors: Introduction of Kinetics Model for Computational Fluid Dynamics Calculations

In our previous work, we used the population balance method to develop a molybdenum disulphide kinetics model consisting of a set of differential equations and constants formulated to express the kinetics of complex chemical reactions leading to molybdenum disulphide precipitation. The purpose of the study is to improved the model to describe the occurring phenomena more thoroughly and have introduced computational fluid dynamics (CFD) modelling to conduct calculations for various reactor geometries. CFD simulations supplemented with our nucleation and growth kinetics model can predict the impact of mixing conditions on particle size with good accuracy. This introduces another engineering tool for designing efficient chemical reactors.     

Dilute-acid pretreatment of corn stover using a high-solids percolation reactor

Pretreatment of corn stover by dilute sulfuric acid was investigated using a laboratory percolation (flowthrough) reactor operated under high-solids conditions. The effects of reaction conditions and operating parameters on the performance of the percolation reactor were investigated seeking the optimal range in which acceptable levels of yield and sugar concentration could be attained. It was demonstrated that 70–75% recovery of xylose and 6 to 7% (w/w) xylose concentration were attainable. The high sugar concentration was obtained as a result of dense packing of dry corn stover and the low liquid throughput. Xylose was mostly unreacted, rather than decomposed. The cellulose and the unreacted xylan of treated corn stover were both effectively hydrolyzed by a “cellulase” enzyme preparation that also exhibits some activity on xylan. The xylose yield was affected significantly by the flow rate under the same reaction time and conditions. This behavior appears to be related to sugar decomposition, mass transfer resistance, and the fact that acid is neutralized by the buffering components of the biomass.     

生物质在微型流化床中热解动力学与机理

利用微型流化床反应分析仪(MFBRA)研究了生物质在氩气氛中的热解反应,通过在线反应物供给和生成气组成变化监测,实现了设定温度下生物质热解反应速率的测试、动力学参数的求算和反应机理的分析。应用该仪器测定的生物质在800℃的热解时间为10s,明显小于传统文献报道值。测试的气体释放顺序与反应动力学参数初步证实了生成的不同气体间存在耦合反应,且各气体生成难易程度存在差异。测试的反应级数为1.62,以整体挥发分为基准的活化能与指前因子分别是11.77kJ/mol和1.45s-1,明显小于常规热重方法的测试值。     

Granulation of activated sludge in a laboratory upflow sludge blanket reactor

The creation of anoxic granulated biomass has been monitored in a laboratory USB (Upflow Sludge Blanket) reactor with the volume of 3.6 L. The objective of this research was to verify the possibilities of post-denitrification of residual NO₃-N concentrations in treated wastewater (denitrification of 10-20 mg L⁻¹ NO₃-N) and to determine the maximum hydraulic and mass loading of the granulated biomass reactor. G-phase from biodiesel production and methanol were both tested as external organic denitrification substrates. The ratio of the organic substrate COD to NO₃-N was 6. Only methanol was proven as a suitable organic substrate for this kind of reactor. However, the biomass adaptation to the substrate took over a week. The cultivation of anoxic granulated biomass was reached at hydraulic loading of over 0.35 m h⁻¹. The size of granules was smaller when compared with results found and described in literary reports (granules up to 1 mm); however, settling properties were excellent and denitrification was deemed suitable for the USB reactor. Sludge volume indexes of granules ranged from 35-50 mL g⁻¹ and settling rates reached 11 m h⁻¹. Maximum hydraulic and mass loadings in the USB reactor were 0.95 m3 m⁻² h⁻¹ and 6.6 kg m⁻³ d⁻¹. At higher loading levels, a wash-out of the biomass occurred. Presented at the 35th International Conference of the Slovak Society of Chemical Engineering, Tatranské Matliare, 26–30 May 2008.     

原料对自由落下床中生物质与煤共热解行为的影响

在500～700℃和生物质混合比0～100％(质量分数)条件下,利用自由落下床反应器考察原料对生物质与煤共热解行为的影响.所用煤原料为大雁褐煤(DY)和铁法烟煤(TF),而生物质原料为农业废弃物秸秆(LS)和木材加工余料白松木屑(SD).结果表明,即使在自由落下床中停留时间短的条件下,生物质与煤共热解的协同效应仍然发生...     

On the Importance of Mixing for the Production of Nanoparticles

The precipitation process of nanoparticles of barium‐sulphate in a confined impinging jet reactor (CIJR) is here modelled by means of a precipitation model based on computational fluid dynamics (CFD). The micromixing was described with the interchange by exchange with the mean model coupled with the direct quadrature method of moments algorithm (DQMOM‐IEM), and the population balance equation (PBE), which describes the nucleation, growth and aggregation steps, was solved with the approach of the quadrature method of moments (QMOM). In this work preliminary results for the validation of the model are presented.     

Design and initial operation of a high-solids,pilot-scale reactor for dilute-acid pretreatment of lignocellulosic biomass

Applied Biochemistry and Biotechnology - A recently installed 100-L horizontal shaft custom-fabricated mixer/reactor, made of Carpenter 20 Cb-3 stainless steel and designed for high-solids,...     

HAZOP study of a fixed bed reactor for MTBE synthesis using a dynamic approach

A methodology for hazard investigation based on the integration of a mathematical model approach into hazard and operability analysis is presented. This approach is based on mathematical modelling of a process unit where both steady-state analysis, including analysis of the steady states multiplicity and stability, and dynamic simulation are used. The dynamic simulation serves for the investigation of consequences of failures of the main controlled parameters, i.e. inlet temperature, feed temperature and feed composition. This simulation is also very useful for the determination of the influence of failure duration on the reactor behaviour. On the other hand, the steady state simulation can predict the reactor behaviour in a wide range of failure magnitude and determine the parametric zones, where shifting from one steady state to another one may occur. A fixed bed reactor for methyl tertiary-butyl ether synthesis was chosen to identify potential hazard and operational problems of a real process. Presented at the 34th International Conference of the Slovak Society of Chemical Engineering, Tatranské Matliare, 21–25 May 2007.