This article presents the liquid-solid mass transfer characteristics for cocurrent upflow operated gas-liquid solid foam packings. Aluminum foam was used with 10, 20, and 40 pores per linear inch (PPI), coated with 5 wt % Pd on c-alumina. The effects of gas velocity (u g ¼ 0.1À0.8 m , which is in the same range as found for random packings and corrugated sheet packings. V V C 2010 American Institute of Chemical Engineers AIChE J, 56: 2923AIChE J, 56: -2933AIChE J, 56: , 2010 Keywords: chemical reactors, mass transfer, multiphase reactors, packed beds, solid foam
IntroductionFor the design of chemical reactors, one has to deal with hydrodynamics, heat and mass transfer, and catalyst activity. For heterogeneously catalyzed reactions, the rate of the reaction is often limited by mass transfer instead of the intrinsic kinetics. The rate-limiting step can be the gas-liquid mass transfer, liquid-solid mass transfer, and intraparticle diffusion. These limitations reduce the overall conversion and selectivity of the process. The effect of mass transfer and diffusion limitation can be reduced by the application of a suitable packing as a catalyst support. Classically, so-called random packings have been used, e.g., porous spherical particles or Berl saddles. However, with structured packings, an even higher selectivity and conversion can be obtained. Different types of packings have been discussed in literature, i.e., monoliths, 1 Sulzer Katapak elements, 2,3 cloths, 4 and fibers.5 A general review describing the different aspects of structured packings (e.g., pressure drop, mass transfer characteristics, residence time distribution) is given by Pangarkar et al. 6 The use of a (structured) packing also overcomes the cumbersome step of catalyst separation, which is often encountered in slurry reactors.Another type of structured packing is the solid foam packing, a highly porous open celled material. The structure of the solid foam resembles the inverse of a packed bed of spherical particles. 7 The average cell size is often expressed in pores per linear inch (PPI). Solid foam is commercially available in a range of 5-100 PPI in a wide variety of materials, e.g., ceramics, metals, plastics, and carbon. The porosity of the solid foam ranges from 80 to 97%.Stemmet et al., [8][9][10] Twigg and Richardson, 11 and Garrido et al. 12 have shown that the pressure drop of solid foam is low compared to the pressure drop of conventional packed beds. Also, high gas-liquid mass transfer rates have been reported, k gl a gl up to 0.6 m 3 l m À3 r s À1 .10 These high mass transfer rates have been attributed to the high interfacial area of the solid foam. In addition to the gas-liquid mass transfer rate, also the liquid-solid mass transfer is important in the design of gas-liquid-solid reactors. Only a limited amount Correspondence concerning this article should be addressed to J. C. Schouten at j.c.schouten@tue.nl. This work focuses on quantifying the liquid-solid mass transfer coefficient for cocurrent gas-liquid upflow through solid fo...