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The ease with which residence time could be adjusted, the absence of moving parts, higher values of heat and
mass transfer coefcient are the attractive features of bubble columns, hence are widely used for conducting several
mass transfer operations/chemical reactions. However selection of sparger design and type is crucial and it affects
performance of the reactor implicitly and explicitly. The Part I of this work addressed the roles of various parameters
to be considered while designing the sparger for bubble column reactors. The second part, deals with the selection of
optimum design and type of the sparger for several designs of bubble column, i.e., effect of column diameter, aspect
ratio, operating pressure and volumetric ow rate of gas phase.
2011 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
Keywords: Bubble column; Sparger; Gas distributor; Spider sparger; Multiple ring sparger; Sieve plate sparger; Radial
sparger; Weeping; Gasliquid reactions
Corresponding author. Tel.: +91 22 33611111/33612222; fax: +91 22 24145614.
E-mail addresses: jbj@udct.org, jbjoshi@gmail.com, jbj@ictmumbai.edu.in (J.B. Joshi).
Received 1 July 2010; Received in revised form 17 October 2010; Accepted 6 January 2011
0263-8762/$ see front matter 2011 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
doi:10.1016/j.cherd.2011.01.014
chemical engineering research and design 8 9 ( 2 0 1 1 ) 19861995 1987
Case 2 0.05 2 4 1
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 5 5625 562.6 3 0.011
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 5 5625 562.6 3 0.011
Wheel Design parameters DC = 0.4 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 26 5642 716.08 2.8 0.0098
Case 3 0.05 2 4 2
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 7 8054 563.2 3.2 0.0098
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 7 7913 579.2 3 0.0099
Wheel Design parameters DC = 0.4 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 26 5642 707.71 3.1 0.0098
Case 4 0.05 2 4 3
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 8 9181 646.3 6.4 0.0094
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 8 9181 646.3 6.4 0.0094
Wheel Design parameters DC = 0.4 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 26 5642 707.71 3.1 0.0098
Case 5 0.05 2 4 5
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 10 11,337 798.2 21.01 0.0089
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 10 11,109 851.2 23.18 0.0089
Wheel Design parameters DC = 0.4 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 26 5642 707.71 3.1 0.0098
Table 4 Effect of operating pressure on sparger design and type for VG 0.1 m/s.
Case No. Operating parameter Supercial gas velocity (m/s) Column diameter (m) Dispersed height (m) Operating pressure (MPa) Average bubble
size (m)
Selected spargers Number of pipes/rings (-) Number of holes (-) Pressure drop (Pa) % Non-uniformity
Case 7 0.1 2 4 1
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 10 11,109 806.7 23.25 0.011
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 10 11,109 806.7 23.23 0.011
Wheel Design parameters DC = 0.4 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 46 9982 903.45 3.1 0.01
Case 8 0.1 2 4 2
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 11 11,870 1570.9 42.98 0.01
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.03 m, do = 2 mm, x/do = 2
Results 12 13,260 1182.5 25.71 0.01
Wheel Design parameters DC = 0.4 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 46 9982 893.62 3.3 0.01
Case 9 0.1 2 4 3
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.03 m, do = 2 mm, x/do = 2
Results 14 15,077 1754.7 44.68 0.01
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.03 m, do = 2 mm, x/do = 2
Results 14 15,077 1754.7 44.68 0.01
Wheel Design parameters DC = 0.4 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 46 9982 893.62 3.3 0.01
Case 10 0.1 2 4 5
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.03 m, do = 2 mm, x/do = 2
Results 15 15,576 2988.8 72.03 0.01
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.03 m, do = 2 mm, x/do = 2
Results 16 16,648 2636 72.6 0.01
Wheel Design parameters DC = 0.4 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 44 9548 972.27 3.4 0.01
1989
1990
Table 5 Effect of operating pressure on sparger design and type for VG 0.2 m/s.
Case No. Operating parameter Supercial gas velocity (m/s) Column diameter (m) Dispersed height (m) Operating pressure (MPa) Average bubble
size (m)
Selected spargers Number of pipes/rings (-) Number of holes (-) Pressure drop (Pa) % Non-uniformity
Case 12 0.2 2 4 1
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.0254 m, do = 2 mm, x/do = 2
Results 16 17,192 2117.9 51.76 0.012
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.03 m, do = 2 mm, x/do = 2
Results 14 15,077 2282.7 44.76 0.012
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 2
Results 50 16,250 1233.45 5.2 0.011
Case 13 0.2 2 4 2
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.0254 m, do = 2 mm, x/do = 2
Results 18 18,687 4332 78.8 0.0116
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.0254 m, do = 2 mm, x/do = 2
Results 18 18,687 4332 78.8 0.0116
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 2
Results 51 16,575 1174.84 5.4 0.011
Case 14 0.2 2 4 3
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.019 m, do = 2 mm, x/do = 2
Results 21 20,839 9399.4 170.8 0.011
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.019 m, do = 2 mm, x/do = 2
Results 21 20,839 9399.4 170.8 0.011
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 2
Results 51 16,575 1174.84 5.4 0.011
Case 15 0.2 2 4 5
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.019 m, do = 2 mm, x/do = 2
Results 23 22,851 11,521.6 171.49 0.011
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.019 m, do = 2 mm, x/do = 2
Results 23 22,851 11,521.6 171.49 0.011
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 2
Results 52 16,900 1132.88 5.4 0.011
Table 6 Effect of operating pressure on sparger design and type for VG 0.4 m/s.
Case No. Operating parameter Supercial gas velocity (m/s) Column diameter (m) Dispersed height (m) Operating pressure (MPa) Average bubble
size (m)
Selected spargers Number of pipes/rings (-) Number of holes (-) Pressure drop (Pa) % Non-uniformity
Case 17 0.4 2 4 1
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.019 m, do = 2 mm, x/do = 2
Results 23 22,851 10,067.1 172.16 0.013
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.019 m, do = 2 mm, x/do = 2
Results 23 22851 10,067.1 172.16 0.013
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 2
Results 98 29400 1867.67 3.5 0.011
Case 18 0.4 2 4 2
Multiple ring 3 Design parameters dH = 0.4 m, dp = 0.019 m, do = 2 mm, x/do = 2
Results 23 27139 29,066.9 246.14 0.014
Multiple ring 4 Design parameters dH = 0.4 m, dp = 0.019 m, do = 2 mm, x/do = 2
Results 23 27139 29,066.9 246.14 0.014
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 2
Results 102 30,600 1723.36 3.5 0.011
Case 19 0.4 2 4 3
Design parameters
Results
Design parameters
Results
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 2
Results 94 28,200 2030.31 3.6 0.011
Case 20 0.4 2 4 5
Design parameters
Results
Design parameters
Results
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 2
Results 91 27,300 2166.59 3.6 0.011
1991
1992
Table 7 Effect of D and HD on sparger design for VG 0.05 m/s.
Case No. Operating parameter Supercial gas velocity (m/s) Column diameter (m) Dispersed height (m) Operating pressure (MPa) Average bubble
Case 2 0.05 2 4 1
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 5 5625 562.6 3 0.011
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 5 5625 562.6 3 0.011
Wheel Design parameters DC = 0.4 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 26 5642 716.08 2.8 0.0098
Case 21 0.05 3 6 1
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 6 10,527 1063.76 13.9 0.0116
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 6 10,527 1063.8 13.85 0.0116
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 33 12,111 1286.32 5.1 0.01
Case 22 0.05 5 10 1
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.038, do = 2 mm, x/do = 2
Results 8 24,346 3205 74.19 0.0123
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.038 m, do = 2 mm, x/do = 2
Results 8 24,346 3205 74.19 0.0123
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 4
Results 54 28,350 1600.13 2.36 0.01
Table 8 Effect of D and HD on sparger design for VG 0.2 m/s.
Case 12 0.2 2 4 1
Multiple ring 3 Design parameters dH = 0.35 m, dp = 0.0254 m, do = 2 mm, x/do = 2
Results 16 17,192 2117.9 51.76 0.012
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.03 m, do = 2 mm, x/do = 2
Results 14 15,077 2282.7 44.76 0.012
Wheel Design parameters DC = 0.5 m, HC = 0.5 m, dp = 0.032 m, do = 1 mm, x/do = 2
Results 50 16,250 1233.45 5.2 0.011
Case 23 0.2 2 6 1
Spider sparger 6 Design parameters dH = 0.35 m, dp = 0.032 m, do = 2 mm, x/do = 2
Results 56 7924 4611.42 58.42 0.0153
Multiple ring 3 Design parameters dH = 0.25 m, dp = 0.0254 m, do = 2 mm, x/do = 2
Results 11 9937 5111.37 33.1 0.0142
Wheel Design parameters DC = 0.6 m, HC = 1 m, dp = 0.0254 m, do = 2 mm, x/do = 4
Results 61 4209 1488.53 4.69 0.019
Case 24 0.2 3 10 1
Multiple ring 3 Design parameters dH = 0.25 m, dp = 0.0254 m, do = 2 mm, x/do = 2
Results 11 17,072 15,021 71 0.0154
Multiple ring 4 Design parameters dH = 0.35 m, dp = 0.0254 m, do = 2 mm, x/do = 3
Results 16 16,632 10,068.9 33.52 0.016
Wheel Design parameters DC = 0.6 m, HC = 1 m, dp = 0.0254 m, do = 1 mm, x/do = 3
Results 95 33,250 2478 7.5 0.011
1993
1994 chemical engineering research and design 8 9 ( 2 0 1 1 ) 19861995
P, non-uniformity and average bubble size) are given for the Comparison of each case in Tables 36 in sequence, i.e.,
selected three spargers in the subsequent rows. The optimum case 1, case 6, case 11, case 16 similarly, case 2, case 7, case 12,
sparger in each case is given in bold face. case 17 and likewise enables us to compare the effect of VG .
The selection of optimum sparger is crucial since several From the design procedure mentioned in Part I the effect of
parameters are required to analyze. It is logical that param- VG is evident, i.e., No increases, hence NP . However it should
eters affecting xed cost of the sparger are dH , dp , NP , and be noticed that wheel type of sparger enables to select the do
No . In all the cases less number of pipes is favorable since of 1 mm, which is not possible for any other sparger.
it inuences the xed cost rather than dp . In all the cases, The effect of D and HD can be found in Tables 7 and 8.
the cost of ring sparger is higher than that of spider, radial As we increase D, the criterion of the non-uniformity attains
and wheel sparger. Comparison of spider and multiple ring importance. The difference in non-uniformity is evident for
sparger based on NP /NR is not advisable since the total length any sparger in all the spargers. Based on similar guidelines
of the pipe (sparging arms) is going to be more or less same mentioned above, wheel type of sparger was found to be
for a specic case and hence only pipe diameter is to be most suitable. Further, this exercise also highlight that for
considered. The parameters P and non-uniformity affect different designs of bubble columns the operating map for
the operating cost and the average bubble size is always sparger design changes hence sparger design changes (com-
the process concern. If the difference in P is higher than pare cases 2 and 21 with 22 in Table 7 and case 12 with 24 in
30%, which implicitly implies the higher non-uniformity, after Table 8).
the due considerations mentioned in Kulkarni et al. (2009)
then aspect ratio should be considered before selecting the 5. Conclusion
optimum sparger type. In any case, less non-uniformity is
desired and the modied multiple ring sparger usually has The present work is concerned with the selection and
less non-uniformity as compared to the modied spider type design of spargers for bubble column reactors over a wide
of sparger. If the difference in the non-uniformity is larger range of design and operating parameters. A systematic
than 30% then the difference in the pressure drop and the analysis for optimum sparger design and type is pro-
detail costing is needed. This formulates the logical basis for vided. It was highlighted that optimum sparger design and
the selection of sparger type for all the cases under consider- type requires process considerations, operational consid-
ation. erations and the fabrication considerations. It was found
The bubble column is operated at higher pressure and/or that wheel type of sparger is most suitable over a wide
higher VG to increase the capacity. The bubble column oper- range of operating and design parameters of bubble column
ated at higher pressure would have relatively less column reactor. However it is to be emphasized that detailed anal-
volume. Similarly an increase in VG also reduces the volume ysis is required for any specic case for optimum sparger
requirement. In the present case, HD was kept constant for the design. Readers are recommended to use the design proce-
sake of illustration, since the objective of the present work is dure given in http://www.4shared.com/le/ptlLFNVX/Sparger-
not to evaluate the different designs of bubble column. Design.html and http://www.esnips.com/web/ICT-Sparger-
Comparison of all the cases in Tables 36 show that an Design.
increase in the P and VG essentially increases the P, since
critical weep velocity increases. This also increases the non-
uniformity, No hence NP . In Table 3, case 1 (VG 0.05 m/s, D 2 m, Acknowledgements
HD 4 m, and P 0.3 MPa) and Table 4, case 6 (VG 0.1 m/s, D 2 m,
HD 4 m, and P 0.3 MPa) the best sparger should be selected The project was supported by a grant from Board of Research
based on the costing of the sparger. This is because, in case in Nuclear Sciences (2006/34/24-BRNS/2803). Dr. Anand V.
1, pipe diameter for wheel sparger is half than that for multi- Kulkarni would like to acknowledge BRNS for their nancial
ple ring sparger and the number of holes required are nearly assistance and also to Mr. Pinaki Ghosh, from IIT Kharagpur
twice than that of multiple ring sparger. The difference in the for his technical assistance during this work.
pressure drop and the average bubble size is not too large in
either case. In Table 5, case 11 (VG 0.2 m/s, D 2 m, HD 4 m, and References
P 0.3 MPa), multiple ring 3 sparger was found to be optimum
sparger. Since, for case 11 the sparger design parameters are Deckwer, W.-D., 1992. Bubble Column Reactors. John Wiley,
dp 0.0254 m, NR 11, and No 11,755, which are favorable as com- England.
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horizontal spargerd contactors. Trans. IChem E. 54,
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