Theory

Overall material and energy balances require various design

parameters representing hydrodynamics of trickle beds such as liquid
holdup, mass and heat transfer coefficients, and axial dispersion.
These hydrodynamic parameters are usually obtained from cold flow
experiments at much smaller scales.
Apart from the flow rates of gas and liquid, prevailing flow regime is also a
function of parameters such as dimensions of the reactor, size and shape of
particles, method of packing, and thermo-physical properties of gas and liquid
phases.
 At moderate gas and liquid flow rates, interaction
among the phases increases and liquid phase occupies
entire flow cross-section. This process leads to the
formation of alternate gas-liquid-enriched zones and
the corresponding regime is classified as pulse flow
regime.
Broader classification of the two-phase flows in the
packed bed reactors is based on the nature of flow of
individual phases viz., continuous, semicontinuous, and
dispersed flow. Four distinct flow regimes were
identified in trickle bed reactors.
 Trickle and pulse flow regimes occur at low-to-moderate flux of gas
and liquid flow rates and industrial reactors are commonly operated
in these flow regimes. Two other flow regimes (spray and bubbly)
may occur at higher gas or liquid flow rates but these are less
common in practical conditions.
 At low gas flow rate and high liquid flow rates, liquid phase occupies entire
portion of the bed and becomes continuous phase while gas phase is
flowing in the form of bubbles in the downward direction. This flow regime
is known as bubbly flow regime.
On the other hand, at low liquid and high gas flow rates, liquid phase
becomes dispersed phase in the form of droplets and gas phase becomes
the continuous phase. This flow regime is known as spray flow regime.
Trickle Flow regime
Trickle flow regime exists at low liquid and moderate gas flow rates
where liquid flows in the form of films or rivulets over the catalyst
particles. At low liquid flow rates, inertial forces are weaker compared
to the local surface forces and liquid spreading is mainly controlled by
capillary pressure. Hence, liquid phase flows in the form of rivulets.
However, at higher flow rates, inertial forces become important as
compared to the interfacial forces (adhesion , capillary); resulting in
film formation over the catalyst surface.
Trickle flow regime region widens with increase in particle size,
decrease in liquid viscosity, and surface tension.
 Advantages:
Low pressure drop, low gas liquid throughputs, less
catalyst attrition and suitability for foaming liquids are
some of the advantages of trickle flow operation.

Disadvantages:
In trickle flow regime, heat and mass transfer rates are
poorer as compared to the other flow regimes. In spite
of these issues, many industrial processes operate in
this regime to achieve the specific process goals (like
higher conversion and productivity).
Pulse Flow Regime
Transition from trickle to pulse flow regime occurs with
increase in either gas flow rate or liquid flow rate. In the pulse
flow regime, local flow path for gas phase is blocked by liquid
pockets/plugs which results in the formation of alternate gas
and liquid-enriched zones.
In the liquid-enriched zones, complete wetting of particles
occurs under this flow regime. Pulse flow regime boundaries
are significantly affected by properties of the liquid, i.e.,
foaming or non-foaming.
In the case of non-foaming liquid, gas and liquid-enriched
zones are quite distinct and visible. Smaller-sized bubbles get
entrapped into the liquid slugs.
In the case of a foaming liquid, liquid slugs contain large sized
gas bubbles and the gas fraction in liquid-rich bands.