Search Results (29)

This study developed a two-dimensional multiphysics-coupled model for co-electrolysis of CO₂ and H₂O in solid oxide electrolysis cells (SOECs) using COMSOL Multiphysics, systematically investigating the influence mechanisms of key operating parameters including temperature, voltage, feed ratio, and flow configuration on co-electrolysis performance. The results demonstrate that increasing temperature significantly enhances CO₂ electrolysis, with the current density increasing over 12-fold when temperature rises from 923 K to 1423 K. However, the H₂O electrolysis reaction slows beyond 1173 K due to kinetic limitations, leading to reduced H₂ selectivity. Higher voltages simultaneously accelerate all electrochemical reactions, with CO and H₂ production at 1.5 V increasing by 15-fold and 13-fold, respectively, compared to 0.8 V, while the water–gas shift reaction rate rises to 6.59 mol/m³·s. Feed ratio experiments show that increasing CO₂ concentration boosts CO yield by 5.7 times but suppresses H₂ generation. Notably, counter-current operation optimizes reactant concentration distribution, increasing H₂ and CO production by 2.49% and 2.3%, respectively, compared to co-current mode, providing critical guidance for reactor design. This multiscale simulation reveals the complex coupling mechanisms in SOEC co-electrolysis, offering theoretical foundations for developing efficient carbon-neutral technologies. Full article

This study aims to contribute to the optimization of bio-methanation in bubble columns, making it a more viable alternative to stirred tank reactors. The primary challenge to be addressed is the enhancement of mass transfer, which strongly depends on parameters such as bubble size and gas hold-up. Various disperser designs were examined in a 0.14 mm diameter column, comparing their performance in terms of bubble diameter distribution and gas hold-up. The results indicate that an optimized plate disperser featuring a porous structure outperformed other designs by maintaining high gas retention without significant coalescence. Additionally, newly developed plug-in dispersers allowed for counter-current flow operation, enhancing process flexibility. Commercially available porous pin dispersers produced smaller bubbles compared to the other designs, yielding high gas hold-ups at lower gas velocities. Correlations between disperser type and column design parameters were established, laying the foundation for apparatus optimization. The findings contribute to the development of digital twin models, facilitating the refinement of bio-methanation processes within bubble columns for increased efficiency. Full article

In this study, in a three-phase reactor with a rectangular cross-section, the effects of liquid circulation rates and solid particle concentration on gas holdup and bubble size distribution (BSD) were investigated. Air, water, and glass beads were used as the gas, liquid, and solid phases, respectively. Different liquid circulation velocities and different solid loads were applied. The results demonstrate that increasing solid content from 0% to 6% can decrease gas holdup by 50% (due to increased slurry phase viscosity and promotion of bubble coalescence). Also, increasing the liquid circulation rate showed a weak effect on gas holdup, although a slight incremental effect was observed due to the promotion of bubble breakup and the extension of bubble residence time. The gas holdup in counter-current slurry bubble columns (CCSBCs) was predicted using a novel correlation that took into account the combined effects of solid concentration and liquid circulation rate. These findings are crucial for the design and optimization of the three-phase reactors used in industries such as mining and wastewater treatment. Full article

Bubble columns are widely used in numerous industrial processes because of their advantages in operation, design, and maintenance compared to other multiphase reactor types. In contrast to their simple design, the generated flow conditions inside a bubble column reactor are quite complex, especially in continuous mode with counter-current liquid flow. For the design and optimization of such reactors, precise numerical simulations and modelling are needed. These simulations and models have to be validated with experimental data. For this reason, experiments were carried out in a laboratory-scale bubble column using shadow imaging and particle image velocimetry (PIV) techniques with and without counter-current liquid flow. In the experiments, two types of gases—relatively poorly soluble air and well-soluble CO₂—were used and the bubbles were generated with three different capillary diameters. With changing gas and liquid flow rates, overall, 108 different flow conditions were investigated. In addition to the liquid flow fields captured by PIV, shadow imaging data were also statistically evaluated in the measurement volume and bubble parameters such as bubble diameter, velocity, aspect ratio, bubble motion direction, and inclination. The bubble slip velocity was calculated from the measured liquid and bubble velocities. The analysis of these parameters shows that the counter-current liquid flow has a noticeable influence on the bubble parameters, especially on the bubble velocity and motion direction. In the case of CO₂ bubbles, remarkable bubble shrinkage was observed with counter-current liquid flow due to the enhanced mass transfer. The results obtained for bubble aspect ratio are compared to known correlations from the literature. The comprehensive and extensive bubble data obtained in this study will now be used as a source for the development of correlations needed in the validation of numerical simulations and models. The data are available from the authors on request. Full article

The two-phase countercurrent flow limitation (CCFL) in horizontal channels is important in relation to nuclear reactor safety. In this study, we aim to investigate the CCFL characteristics and the flow behaviors in horizontal circular pipes with small diameters. The effects of pipe diameter and the water head in the upper plenum on CCFL characteristics are experimentally studied. An image-processing technique and statistical treatments are implemented to analyze the horizontal countercurrent flow. The results show that the CCFL characteristics for the horizontal circular pipes with small diameters can be well correlated using the dimensionless parameters, which are based on adding fluid viscosity to the Wallis parameters. The CCFL characteristics are significantly affected by the pipe diameter and are slightly affected by the water head above the horizontal pipe. The gas–liquid interface fluctuates with certain periods, and flow pattern transitions happen in the horizontal air–water countercurrent flow. As the air flow rate increases, the occurrence location of the liquid slug appears to shift towards the water entrance. In addition, the further away from the water entrance, the lower the average of liquid holdup. Full article

The leaching of Cu in ammoniacal solutions has proven an efficient method to recover Cu from waste printed circuit boards (WPCBs) that has used by many researchers over the last two decades. This study investigates the feasibility of a counter-current leaching circuit that would be coupled with an electrowinning (EW) cell. To accomplish this objective, the paper is divided into three parts. In Part 1, a leaching kinetic framework is developed from a set of experiments that were designed and conducted using end-of-life waste RAM chips as feed sources and Cu(II)-ammoniacal solution as the lixiviant. Various processing parameters, such as particle size, stirring rates, initial Cu(II) concentrations, and temperatures, were evaluated for their effects on the Cu recovery and the leaching rate. It was found that the particle size and initial Cu(II) concentration were the two most important factors in Cu leaching. Using a 1.2 mm particle size diameter and 40 g/L of initial Cu(II) concentration, a maximum Cu recovery of 96% was achieved. The Zhuravlev changing-concentration model was selected to develop the empirically fitted kinetic coefficients. In Part 2, kinetic data were adapted into a leaching function suitable for continuously stirred tank reactors. This was achieved via using the coefficients from the Zhuravlev model and adapting them to the Jander constant concentration model for use in the counter-current circuit model. Part 3 details the development of a counter-current circuit model based on the relevant kinetic model, and the circuit performance was modeled to provide a tool that would allow the exploration of maximum copper recovery whilst minimizing the Cu(II) reporting to electrowinning. A 4-stage counter-current circuit was modeled incorporating a feed of 35 g/L of Cu(II), achieving a 4.12 g/L Cu(II) output with 93% copper recovery. Full article

In recent years, gasification gained attention again, both as an industrial application and as a research topic. This trend has led to the necessity to understand the process and optimize reactors for various materials and configurations. In this article, the thermal structure of a counter-current reactor is investigated to demonstrate that constraints on the temperature mainly determine the oxidation and the pyrolysis region. A non-dimensional set of equations is written and numerically solved using the method of lines (MOL) with spatial discretization based on a spectral algorithm. The results show that four thermal structures can be identified, two of which are the most common ones found in reactors of practical applications. Two stationary operation positions have been determined, one in the upper and one in the lower part of the reactor. Existence and stability conditions have been discussed based on non-dimensional parameters. The knowledge derived from this analysis was applied to two configurations, one typical of a biomass gasifier and one proposed for waste gasification. Full article

In this paper, a series of equilibrium and kinetic experiments of Hg(II) removal in a single-stage batch reactor on natural (NZ) and sulfur-impregnated zeolite (SZ) were performed. Batch sorption of Hg(II) on zeolites was studied using different isothermal and kinetic models. It was found to be best described by the Brouers-Sotolongo isotherm and the Vermeulen’s approximation, which were applied in optimizing the mass and contact time in two-stage cross-current and counter-current flow batch reactors based on the desired criterion of 99.9% removal efficiency. Mathematical models for minimizing zeolite mass and contact time were developed and experimentally verified. The optimum minimum masses of NZ and SZ were calculated for all systems, and a significant saving in SZ consumption was found when the counter-current design was applied. The toxicity characteristic leaching procedure (TCLP) was applied to mercury contaminated soil from the Idrija mine region in Slovenia to evaluate potential soil toxicity. The results showed that the soil is extremely contaminated and represents hazardous waste. The addition of zeolites significantly reduced the concentration of leached Hg, with the most satisfactory results obtained with SZ. It was found that at the lowest dose of 0.25 g of SZ, the leached Hg concentration was reduced below the maximum concentration criterion of 0.2 mg/L according to the TCLP test. This study revealed that SZ could be a potential sorbent for in situ remediation of mercury contaminated soil. Full article

Gas–liquid two-phase countercurrent flow limitation (CCFL) phenomena widely exist in nuclear power plants. In particular, the gas–liquid countercurrent flow limitation phenomena in a pressurized water reactor (PWR) during a loss-of-coolant accident (LOCA) or a small-break loss-of-coolant accident (SBLOCA) play an important role in nuclear reactor safety research. Over several decades, a series of experimental investigations and numerical studies have been carried out to study the CCFL phenomena in a PWR. For the experimental investigations, numerous experiments have been conducted, and different CCFL mechanisms and CCFL characteristics have been obtained in various test facilities simulating different scenarios in a PWR. The CCFL phenomena are affected by many factors, such as geometrical characteristics, liquid flow rates, and fluid properties. For the numerical studies, more and more numerical models were presented and applied to the calculations of two-phase countercurrent flow over the past several decades. It is considered that the computational fluid dynamics (CFD) tools can simulate most of the two-phase flow configurations encountered in nuclear power plants. In this paper, the experimental investigations and the numerical studies on two-phase countercurrent flow limitation in a PWR are comprehensively reviewed. This review provides a further understanding of CCFL in a PWR and gives directions regarding future studies. It is found that relatively fewer investigations using steam–water under high system pressures are performed due to the limitation of the test facilities and test conditions. There are a number of numerical studies on countercurrent two-phase flow in a PWR hot leg geometry, but the simulations in other flow channels were relatively rare. In addition, almost all of the numerical simulations do not include heat and mass transfer. Thus, it is necessary to investigate the effects of heat and mass transfer experimentally and numerically. Furthermore, it is of significance to perform numerical simulations for countercurrent two-phase flow with a fine computational grid and suitable models to predict the formation of small waves and the details in two-phase flow. Full article

The production of catalysts such as zeolites is a complex multiscale and multi-step process. Various material properties, such as particle size or moisture content, as well as operating parameters—e.g., temperature or amount and composition of input material flows—significantly affect the outcome of each process step, and hence determine the properties of the final product. Therefore, the design and optimization of such processes is a complex task, which can be greatly facilitated with the help of numerical simulations. This contribution presents a modeling framework for the dynamic flowsheet simulation of a zeolite production sequence consisting of four stages: precipitation in a batch reactor; concentration and washing in a block of centrifuges; formation of droplets and drying in a spray dryer; and burning organic residues in a chain of rotary kilns. Various techniques and methods were used to develop the applied models. For the synthesis in the reactor, a multistage strategy was used, comprising discrete element method simulations, data-driven surrogate modeling, and population balance modeling. The concentration and washing stage consisted of several multicompartment decanter centrifuges alternating with water mixers. The drying is described by a co–current spray dryer model developed by applying a two-dimensional population balance approach. For the rotary kilns, a multi-compartment model was used, which describes the gas–solid reaction in the counter–current solids and gas flows. Full article

The necessity of economical and rational use of natural energy sources caused a rapid development of research on the possibilities of using non-conventional energy resources. Taking the above into account, a new technological process of thermochemical conversion of biomass and communal waste, commonly known as High Temperature Air/Steam Gasification (HTA/SG) and Multi-Staged Enthalpy Extraction Technology (HTAG-MEET), was developed. In relation to traditional techniques of gasification or combustion of hydrocarbon fuels, the presented concept is characterized by higher thermal efficiency of the process, low emission of harmful compounds of carbon, sulfur, nitrogen, dioxins, furans and heavy metals. The use of a high-temperature gasification factor causes an increased thermochemical decomposition of solid fuels, biomass and municipal waste into gaseous fuel (syngas), also with increased hydrogen content and Lower Calorific Value (LCV). In this study, the possibility of using a batch type reactor (countercurrent gasifier) was analyzed for gasification of biomass and municipal waste in terms of energy recovery and environmental protection. The proposed research topic was aimed at examining the possibility of using the thermal utilization of biomass and municipal waste through their high-temperature decomposition in the presence of air, a mixture of air and steam. The main goals of the research were achieved during the implementation of several parallel stages of the schedule, which included, primarily: (a) study of the possibility of using thermal utilization of biomass and municipal waste through their high-temperature gasification in the presence of air or a mixture of air and steam and, secondary (b) analytical and numerical modeling of high-temperature gasification of biomass and municipal waste with the use of ANSYS CFD Fluent 6.3 software. Selected results of the experimental and numerical studies are properly presented. The higher temperature gasification concept shows the capability of this technology for maximizing the gaseous product yield in an up-draft fixed bed gasifier. It was also observed that at a high temperature, steam addition contributed to the thermal conversion of biofuels to gas with higher production of hydrogen. Full article

The paper compares conceptual designs of a microstructured reactor/heat-exchanger for the small-scale production of C₈₊ range hydrocarbons from methanol over H-ZSM-5 catalytic coatings. In these designs, air was used as a cooling fluid in the adjacent cooling channels. The heat transfer characteristics of a single-zone reactor (with channels 500 $\mathsf{\mu }$m in diameter) and a two-zone reactor (with an additional coolant inlet) have been compared. A single reaction zone was not able to reduce the temperature gradient below 15 K, while a two-zone configuration, with a counter-current fluid flow in the upstream section and co-current flow in the downstream section, demonstrated a near-isothermal behaviour, with a mean temperature of 653 K. Full article

The subject of this work is the mathematical modelling of a counter-current moving-bed gasifier fuelled by wood-pellets. Two versions of the model have been developed: the one-dimensional (1D) version-solving a set of Ordinary Differential Equations along the gasifier height-and the three-dimensional (3D) version where the balanced equations are solved using Computational Fluid Dynamics. Unique procedures have been developed to provide unconditionally stable solutions and remove difficulties occurring by using conventional numerical methods for modelling counter-current reactors.The procedures reduce the uncertainties introduced by other mathematical approaches, and they open up the possibility of straightforward application to more complex software, including commercial CFD packages. Previous models of Hobbs et al., Di Blasi and Mandl et al. used a correction factor to tune calculated temperatures to measured values. In this work, the factor is not required. Using the 1D model, the Mandl et al. 16.6 kW gasifier was scaled to 9.5 MW input; the 89% cold-gas efficiency, observed at 16.6 kW input, decreases only slightly to 84% at the 9.5 MW scale. Full article

This research presents 3D steady-state simulations of a skim milk spray drying process in a counter-current configuration dryer. A two-phase flow involving gas and discrete phase is modeled using the Eulerian–Lagrangian model with two-way coupling between phases. The drying kinetics of skim milk is incorporated using the Reaction Engineering Approach. The model predictions are found to be in accordance with the experimental temperature measurements with a maximum average error of 5%. The validated computational model is employed further to study the effects of nozzle position, initial spray Sauter Mean Diameter (SMD), air inlet temperature, and feed rate on the temperature and moisture profiles, particle impact positions, drying histories, and product recovery at the outlet. The location of the nozzle upwards (≈23 cm) resulted in maximum product recovery and increased the mean particle residence time at the outlet. A similar trend was observed for the highest feed rate of 26 kg/h owing to the increased spray penetration upstream in the chamber. The maximum evaporation zone was detected close to the atomizer (0–10 cm) when the spray SMD is 38 µm, whereas it shifts upstream (40–50 cm) of the dryer for an SMD of 58 µm. The high air inlet temperature resulted in enhanced evaporation rates only in the initial 10–20 cm distance from the atomizer. The results obtained in this study are beneficial for the development of the novel vortex chamber-based reactors with a counter flow mechanism. Full article

Ultrasonic spraying was used in a three-phase reactor to produce small droplets of triolein mixed with CaO as a solid catalyst at temperatures above the boiling point of methanol for enhancement of the transesterification of triolein. Droplets fell in the methanol countercurrent flow and were collected at the bottom of the reactor, followed by circulation to the ultrasonic spray system. The experimental parameters included triolein flow rates of 2.5–9.0 mL/min, reaction temperatures of 70–100 °C, and catalyst contents of 1.0–7.0 wt%. The methanol feed rate was set to be constant. The results suggested that the enhancement was successful after using the three-phase reactor by generating a high contact surface area for the droplets, which was a key factor for determining the performance. Comparing the results with conventional transesterification in the liquid phase using the same CaO at 60 °C, the three-phase reactor produced a methyl ester yield 2–5% higher during the 60 min trial period. However, the yield became lower after 60 min because the mass transfer of methanol to the droplets was limited. The transesterification kinetics were estimated based on the experimental data—assuming a first-order reaction—and the results indicated a range of the rate constant, an apparent activation energy, and a pre-exponential factor of 1.21–3.70 × 10⁻² min⁻¹, 36.1 kJ mol⁻¹, and 64.9 min⁻¹, respectively, suggesting that the three-phase reactor was effective for fast transesterification at the initial stage. Full article