2008 international ansys conference...– main reactions: zero order with gaseous reactant (beyond a...
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© 2008 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary
2008 International ANSYS Conference
Improving Multiphase Reactors
Vivek V. Ranade*Tridiagonal Solutions Pvt. Ltd.100 NCL Innovation Park, Pune, Indiawww.tridiagonal.co.in* On leave from National Chemical Laboratory, Pune, India
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© 2008 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary
Industrial Reactors
• What transformations are expected to occur?• How fast these transformations will occur?• What is the best way to carry out these
transformations?
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© 2008 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary
Reactor Performance
• Performance Matrix • Performance Controlling Processes
– Mixing of reactants– Heat transfer– Contacting of multiple
phases– Mass transfer– Chemical reactions– Phase changes
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© 2008 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary
Improving Reactor Performance
• RAPIDTM Program*: Reactor Analysis and Performance Improvement Diagnostics
– Critical analysis of laboratory and plant data– Mathematical modeling– Identify performance controlling step(s)– Evolving ideas for improvement– Computational evaluation of evolved ideas– Fine tuning and implementation
* Proprietary program of Tridiagonal Solutions Pvt. Ltd.
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© 2008 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary
The RAPIDTM Methodology
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© 2008 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary
Simulating Reactor Performance
• Link reactor performance to reactor hardware and operating protocols
– Solution of mass, momentum & energy conservation equations: CFD
Concentration profiles over time
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© 2008 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary
Modeling and Simulation
• Uncertainties / Limitations– Inadequacies of the underlying mathematical model &
input data• Turbulence/ multiphase flows/ complex rheology/ reactions
– Inaccuracies of the numerical techniques– Computational constraints– Interpretation of results
• Despite the Limitations, Computational Modeling has Enormous Potential !
Necessary to develop appropriate methodology to harness this potential
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© 2008 ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary
Harnessing Power of Modeling
• Need to Develop & Use Multi-scale Modeling Capabilities
• Need to Use Multiple Models & Modeling Technologies
• Tridiagonal’s Approach of Compute for Innovation & Development
Tools+
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© 2008 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary
Case Study: G-L-S Reactor
• Reactions– In presence of gaseous reactant
– Main reactions: zero order with gaseous reactant (beyond a critical concentration)
– Undesired reactions: NOT zero order– ‘B’ precipitates due to low solubility– Influenced by temperature and pH
A B C (desired product)
D (undesired products) E
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© 2008 ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary
G-L-S Reactor
• Need to understand and quantify time scales of different reactions and processes
– Concentration of gaseous reactant• Mass transfer: dispersion of gas, hold-up, (P/M)
– Dissolution of solids• Suspension/ solid-liquid mass transfer
– Temperature• Heat transfer: direct contact, jacket
– pH• Mixing
Need to quantitatively
understand multi-phase fluid dynamics
of GLS reactor
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© 2008 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary
CFD Model of Existing Reactor
• Eulerian-Eulerian Approach– Single effective bubble size based on estimates of
interfacial area– Inter-phase coupling: need to include impact of
impeller generated turbulence• Drag coefficient as a function of Re and (dp/λ)
• Turbulent Flow– Two equation (dispersed phase) models
• Multiple Reference Frame approach
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© 2008 ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary
• Semi-batch reactor operation– Quantify Influence of
• Gas flow rate• Power per unit mass/ tip speed• pH• Addition rates• Operating temperature
Kinetics via Laboratory Experiments
Obtained simplified kinetic model0
0.1
0.2
0.3
0.4
0.5
0.6
0 5 10 15 20 25 30Time (hr)
Key
reac
tant
con
cent
ratio
n (m
ol/li
t)
Plant dataModel
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© 2008 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary
Scale-up
• Translating findings from the laboratory reactor (5 lit) to the plant reactor (> 50 m3)– Develop and use CFD model to understand gas-liquid-solid flow in
industrial stirred vessel– Determine how key time and length scales change with increase in
reactor volume– Evolve ideas for improving performance
• Configuration, size and RPM of impeller(s)• Location of feed nozzles: gas, alkali and diluents• Manipulate heat transfer for desired temperature profile
– Evaluate and fine tune the recommendation
• Using GAMBIT and FLUENT
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© 2008 ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary
Reactor Configuration
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© 2008 ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary
Indirect Validation
• Power dissipation with and without gas • Pumping numbers with and without gas• Mixing
– pH measurements at different locations after alkali addition
• Overall gas hold-up
• Accepted CFD model with identified– Drag coefficients (on bubbles and solids), effective
bubble size, numerical parameters and strategies
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© 2008 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary
Gaining Insight via CFD I
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© 2008 ANSYS, Inc. All rights reserved. 17 ANSYS, Inc. Proprietary
Gaining Insight via CFD II
• Understanding mixing for manipulating pH
• Influence of alkali addition nozzle (size/ location) and influence of reactor scale was investigated
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© 2008 ANSYS, Inc. All rights reserved. 18 ANSYS, Inc. Proprietary
Gaining Insight via CFD III
• Influence of sparger (size/ location) and influence of reactor scale was investigated
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© 2008 ANSYS, Inc. All rights reserved. 19 ANSYS, Inc. Proprietary
Improving Mixing
• Alkali addition sequence and mixing (prevailing pH) had significant influence on– Yield of desired product– Overall rate– Foaming
• CFD Model was used to improve mixing by– Manipulating impeller locations/ RPM– Designing foam breaker to ensure trouble free
operation
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© 2008 ANSYS, Inc. All rights reserved. 20 ANSYS, Inc. Proprietary
Improving Mass Transfer
• Gas-liquid (mainly for the first step) and solid-liquid (for the second step) mass transfer were important. Using developed CFD models:
– Identified roles of different impellers & manipulated locations and clearance between the two impellers
– Modified configuration and location of gas sparger– Special care was taken to handle accumulation of
precipitated solids on foam surface
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© 2008 ANSYS, Inc. All rights reserved. 21 ANSYS, Inc. Proprietary
Realizing Performance Enhancement
• Dilution strategy and pH profile was manipulated to realize– Significant reduction in batch time– Some increase in yield of desired product
• CFD model was used to identify most attractive alternative to realize performance enhancement with minimum investment for retrofitting
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© 2008 ANSYS, Inc. All rights reserved. 22 ANSYS, Inc. Proprietary
Summary
• CFD models and simulations provided valuable insight in understanding relevant time scales & rate controlling steps
• CFD simulations allowed virtual evaluation of alternative ideas to identify most effective solution for practical implementation
Tremendous Potential for Realizing Performance Enhancement in Practice by Judicious Use of CFD