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Volume 9
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10.3390/chemengineering9060144
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Article

Numerical Investigation into Effects of Gas Sparger and Horizontal Baffles on Hydrodynamics of Flat Bubble Column

by
Masroor Abro
1,2,*,
Imran Nazir Unar
2,3,
Junaid Korai
4,
Abdul Qudoos
5,
Sikandar Almani
2,
Abdul Qadeer Laghari
2,
Liang Yu
6 and
Abdul Sattar Jatoi
7
1
Beijing Key Laboratory of Membrane Science & Technology, College of Chemical Engineering, Beijing University of Chemical Technology, Beijing 100029, China
2
Process Simulation and Modeling Research Group, Chemical Engineering Department, Mehran University of Engineering and Technology, Jamshoro 76062, Pakistan
3
Nuclear and Plasma Radiological Engineering Department, Grainger College of Engineering University of Illinois Urbana-Champaign, Urbana, IL 61801, USA
4
Departament d′Enginyeria Química, Universitat Rovira i Virgili, Avinguda Països Catalans 26, 43007 Tarragona, Spain
5
Centre of Carbon Capture, Utilisation and Storage (CCCUS), Institute of Sustainable Energy and Resources (ISER), Universiti Teknologi Petronas, Bandar Seri Iskandar 32610, Malaysia
6
Agricultural and Biological Engineering, School of Engineering and Technology, Kentucky State University, Frankfort, KY 40601, USA
7
Chemical Engineering Department, Dawood University of Engineering and Technology, Karachi 74800, Pakistan
*
Author to whom correspondence should be addressed.
ChemEngineering 2025, 9(6), 144; https://doi.org/10.3390/chemengineering9060144
Submission received: 17 October 2025 / Revised: 30 November 2025 / Accepted: 9 December 2025 / Published: 12 December 2025
Versions Notes

Abstract

Computational fluid dynamics (CFD) was used to investigate influence of different gas sparger configurations and the presence of horizontal baffles on hydrodynamic characteristics in a flat bubble column. CFD results of time-averaged local and global gas holdup, liquid axial velocity, and Sauter mean diameter were experimentally validated. Subsequently, the validated CFD model was extended to investigate the effects of different gas sparger configurations, i.e., S1, S3, S4, S5, S8, and S72, and baffles arrangements, i.e., Config-A and Config-B on overall hydrodynamics at different superficial gas velocities (Ug= 0.0014 m/s and 0.0073 m/s). CFD results demonstrated significant influence of both sparger and Ug. Gas holdup and interfacial area increased with smaller, more numerous sparger openings, such that S72 achieved ~1.55 times higher holdup and ~2 higher interfacial area than that of S1. Spargers with fewer and larger openings induced stronger turbulence, which intensified early breakup and coalescence and broadened the bubble size distribution. Results revealed that spargers with many small openings (S72) produced the narrowest distribution, retaining a high fraction of bubbles of initial size (5 mm), whereas spargers with fewer larger openings (S1) generated broader distributions with significant coalescence, especially at higher Ug. The inclusion of baffles enhanced liquid circulation and gas–liquid mixing and contact. However, intensified turbulence below each baffle significantly increased coalescence, producing larger bubbles and resulting in only marginal changes in interfacial area despite increased gas holdup.
Keywords: bubble column; CFD modeling; bubble size distribution; gas sparger; baffles bubble column; CFD modeling; bubble size distribution; gas sparger; baffles

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MDPI and ACS Style

Abro, M.; Unar, I.N.; Korai, J.; Qudoos, A.; Almani, S.; Laghari, A.Q.; Yu, L.; Jatoi, A.S. Numerical Investigation into Effects of Gas Sparger and Horizontal Baffles on Hydrodynamics of Flat Bubble Column. ChemEngineering 2025, 9, 144. https://doi.org/10.3390/chemengineering9060144

AMA Style

Abro M, Unar IN, Korai J, Qudoos A, Almani S, Laghari AQ, Yu L, Jatoi AS. Numerical Investigation into Effects of Gas Sparger and Horizontal Baffles on Hydrodynamics of Flat Bubble Column. ChemEngineering. 2025; 9(6):144. https://doi.org/10.3390/chemengineering9060144

Chicago/Turabian Style

Abro, Masroor, Imran Nazir Unar, Junaid Korai, Abdul Qudoos, Sikandar Almani, Abdul Qadeer Laghari, Liang Yu, and Abdul Sattar Jatoi. 2025. "Numerical Investigation into Effects of Gas Sparger and Horizontal Baffles on Hydrodynamics of Flat Bubble Column" ChemEngineering 9, no. 6: 144. https://doi.org/10.3390/chemengineering9060144

APA Style

Abro, M., Unar, I. N., Korai, J., Qudoos, A., Almani, S., Laghari, A. Q., Yu, L., & Jatoi, A. S. (2025). Numerical Investigation into Effects of Gas Sparger and Horizontal Baffles on Hydrodynamics of Flat Bubble Column. ChemEngineering, 9(6), 144. https://doi.org/10.3390/chemengineering9060144

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