TRICKLE BED REACTOR

Foreword

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This manual explains the working of equipment. Please read it thoroughly and have all
the occupants follow the instructions carefully. Doing so will help you enjoy many years
of safe and trouble free operation.

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and is interested in your complete satisfaction. We will provide the quality maintenance
and any other assistance you may require.

All the information and specifications in this manual are current at the time of printing.
However, Because of K.C. Engineers policy of continual product improvement we
reserve the right to make changes at any time without notice.

Please note that this manual explains all about the equipment including options.
Therefore you may find some explanations for options not installed on your equipment.

You must follow the instructions and maintenance instructions given in the manual
carefully to avoid possible injury or damage. Proper maintenance will help ensure
maximum performance, greater reliability and longer life for the product.

K.C. Engineers
 Contents

1. Objective …………………………………… 1

2. Aim …………………………………… 1

3. Introduction …………………………………… 1

4. Theory …………………………………… 1

5. Description …………………………………… 3

6. Utilities Required …………………………………… 4

7. Experimental Procedure …………………………………… 4

8. Observation & Calculation …………………………………… 4

9. Nomenclature …………………………………… 6

10. Precautions & Maintenance Instructions …………………………………… 7

11. Troubleshooting …………………………………… 7

12. References ……………………………………. 8

Trickle Bed Reactor

 TRICKLE BED REACTOR

1. OBJECTIVE
Hydrodynamic studies on a Trickle Bed Reactor.

2. AIM:
To measure the variation in two-phase pressure drops by passing liquid & gas in a
Trickle Bed Reactor at various flow rates.

3. INTRODUCTION:
Two phase flow is important in many areas of chemical & process engineering & the
behavior of the material will depend on the properties of the components & flow-rates
& the geometry of system. Mixed materials may be transported horizontally,
vertically or at an inclination to the horizontal in pipes. Although there is some degree
of common behavior between the various cases, the range of physical properties is so
great that each different type of system must be studied separately. For all multiphase
flow systems, it is important to understand the nature of the interactions between the
phases & how these influence the flow patterns- the ways in which the phases are
distributed over the cross section. In design it is necessary to be in a position to
predict pressure drop which, usually, will depend not only on the flow pattern, but
also on the relative velocity of the phases.

4. THEORY:
Co-current flow of gas & liquid (usually downward) through packed beds is used for
catalytic chemical reaction between components of the fluids, the catalyst usually
being some active substance supported upon granular ceramic material. Such
arrangements are known as Trickle bed reactors.
A trickle bed reactor is a fixed bed reactor with two-phase flow. Liquid phase and gas
phase flow concurrently downward through a fixed bed of catalysts. The study of
hydrodynamics of Trickle Bed Reactor is required to evaluate the reactor
performance, size and energetic requirements. The main hydrodynamic parameters
that affect Trickle Bed Reactor operation include: Pressure Drop, Hold-up and
Regime Transition.

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 FLOW TRANSITION:
Mostly the flow regimes are detected by visual observation of the flow pattern
through the transparent column wall. However, other techniques such as electro
conductivity, thermo conductivity, pressure drop measurements and variation in mass
transfer coefficient are also used. There are two main hydrodynamic regimes, namely:
1) Low interaction regime
2) High interaction regime.
The transition between these two regimes is characterized by sudden increase in two-
phase pressure drop.
TWO-PHASE PRESSURE DROP:
The most widely used method for estimating the drop in pressure due to friction is
that proposed by Lockhart Martinelli. This is based on the physical model of
separated flow in which each phase is considered separately & then a combined effect
formulated. The two phase pressure drop due to friction (-∆PTPF) is taken as the
pressure drop (-∆PL) or (-∆PG) that would arise for either phase flowing alone in the
pipe at the stated rate, multiplied by some factor φ L2 or φ G2 . This factor is presented
as a function of the ratio of the individual single
Phase pressure drops.

(− ∆PTPF ) (− ∆PTPF ) (− ∆PL )

φL = φG = & X =
(− ∆PL ) (− ∆PG ) (−∆PG )

The value of L-M parameter X can also be calculated using Larkin’s as below:
 ∆PTPF  0.416
log  =
 ∆PL + ∆PG  (log X ) + 0.666
2

The relation between ϕG/ϕL and X is shown in the figure below:

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 To calculate value of ϕL/ϕG from the above graph it is necessary to find modified
Reynolds number for both the streams.
DP ρ GVG
Re G =
( µ G (1 − ε ))

D P ρ LV L
Re L =
( µ L (1 − ε ))

Also, Chisholm has developed a relation between ϕL & X which he puts in the form:
c 1
φ L2 = 1 + + 2
X X
Where c has a value of 20 for turbulent flow, 12 for streamline liquid/turbulent gas,
10 for turbulent liquid/streamline gas & 5 for streamline/streamline flow.

5. DESCRIPTION:
The experimental set-up consists of a Borosilicate Glass Column, filled with Glass
Beads. Inlet for gas and liquid phase is provided at the top of the column. Air from
compressor and surge tank is saturated with water in a saturator before entering the
packed bed, to avoid mass transfer between gas and liquid phase inside the column. A
liquid distributor is provided at the top of the packed section. The packing in the
column is supported on a mesh. The feed liquid to the column is pumped by means of
a Centrifugal Pump, from the Sump Tank via standard Water Rotameter. Quick
closing valves are provided at liquid, gas inlets and at the bottom of the column. To
measure the pressure drop, two U-tube manometers (one each for upstream &
downstream), are provided.

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6. UTILITIES REQUIRED:
Electricity Supply: Single Phase, 220 VAC, 50Hz, 0.5 kW with earth connection.
Compressed Air Supply at 4 Bar, 2.5 CFM.
Water Supply.
Drain.
Bench Area Required: 1.5 x 0.75 m.
CCl4 50ml (for manometer)

7. EXPERIMENTAL PROCEDURE:
1. Fill the Glass beads in the column up to a desired height & note the height.
2. Fill the sump tank (2/3) rd with water.
3. Start the compressor and develop air pressure in the surge tank around 1 kg/cm2.
During this period keep air and water inlets close.
4. Note the ambient temperature of water and air.

5. Allow water to enter the Trickle bed Reactor so that the complete packing is wet
by opening the water inlet valve. Note the pressure drop (h cm of manometer
fluid) & flow rate.

6. Stop the water supply & start air supply & Note the pressure drops (h cm of
manometer fluid) & flow rate.

7. Now start both streams & Wait for the steady state to reach

8. Record the air flow rate and water flow rate. Also record the pressure drop across
the packed section (h cm of manometer fluid).
9. Repeat above steps for at least 4 liquid rates & 4 gas rates.

8. OBSERVATIONS & CALCULATIONS:

DATA:
DP = -------m
φ = -------
ε = -------
D = -------m
A = -------m2
ρm = -------kg/m3
ρG = -------kg/m3

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 ρL = ------- kg/m3
Z = -------m
µG = ------- N s/m2
µL = --------- N s/
Tw = -------- °C
Ta = -------- °C

OBSERVATION TABLE:

Liquid phase Pressure drop:

QL RL (in cm of CCl4) RL, m

(LPH) Upper manometer Lower manometer
u1 u2 l1 l2

Gas phase Pressure drop:

QG RG (in cm of CCl4) RG, m

(LPM) Upper manometer Lower manometer
u1 u2 l1 l2

Two phase Pressure drop:

QG QL RTPF (in cm of CCl4) RTPF

(LPM) (LPH) Upper Lower
manometer manometer
u1 u2 l1 l2

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 CALCULATIONS:

QG × 10 −3
VG = , m/s = ------------- m/s
A × 60

QL × 10 −3
VL = , m/s = --------------- m/s
A × 60

DP × VG × ρ G
Re G = = ----------------
µ G (1 − ε )

DP × VL × ρ L
Re L = = ------------
µ L (1 − ε )

R 
∆PL =  L [(ρ m − ρ L ) × g ] , N/m2 = ------------ N/m2
 100 

R 
∆PG =  G [(ρ m − ρ G ) × g ] , N/m2 = ------------ N/m2
 100 

R 
∆PTPF =  TPF [(ρ m − ρ G ) × g ], N/m2 = ------------ N/m2
 100 

∆PTPF = Φ L × ∆PL or Φ G × ∆PG , N/m2 = -------------- N/m2

2 2

9. NOMENCLATURE:
Ac = Cross sectional area of the column, m2
D = Column diameter, m
DP = Diameter of glass beads, m
l1 = RHS reading of lower manometer, m
l2 = LHS reading of lower manometer, m
∆PTPF = Experimental & theoretical two phase pressure drop, N/m2
∆PL = Liquid phase pressure drop, N/m2
∆PG = Gas phase pressure drop, N/m2
QG = Gas flow rate, LPM
QL = Water flow rate, LPH
RL = Liquid phase pressure drop (in cm of CCl4), m
RG = Gaseous phase pressure drop (in cm of CCl4), m
RTPF = Two phase pressure drop (in cm of CCl4), m
ReG = Gaseous phase modified Reynolds number

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 ReL = Liquid phase modified Reynolds number
Ta = Temperature of air, °C
Tw = Temperature of water, °C
u1 = RHS reading of upper manometer, m
u2 = LHS reading of upper manometer, m
VG = Superficial velocity of gas phase, m/s
VL = Superficial velocity of liquid phase, m/s
Z = Height of packing between manometric taps, m
ε = Porosity of the trickle bed
φ = Drag ratio for two phase flow
µG = Viscosity of gas phase at ambient conditions, N s/m2
µL = Viscosity of liquid phase at ambient conditions, N s/m2
ρG = Density of gas phase at ambient conditions, kg/m3
ρL = Density of liquid phase at ambient conditions, kg/m3
ρm = Density of manometer liquid (CCl4), kg/m3

10. PRECAUTIONS & MAINTENANCE INSTRUCTIONS:

1. Never run the apparatus if power supply is less than 180 volts and above than
230 volts
2. Avoid closing Delivery & By-Pass valves simultaneously.
3. Always use clean water.
4. To prevent clogging of moving parts, Run Pump at least once a fortnight.
5. It apparatus will not in use for more than one month, drain the apparatus
completely, and fill pump with cutting oil.
6. Always keep apparatus free from dust.

11. TROUBLESHOOTING:
1. In case of any problem regarding operation of the apparatus; the apparatus
should be quickly switched OFF and electric supply should be cut off.
2. Electric Shock: It means that either earth wire inside the panel is loose or there
is no earth provided in the socket to which the equipment is plugged. So, make
it sure that the equipment is earthed properly.
3. Leakage: The point of leakage should be detected & the concerned part is
tightened properly. If the problem still persists then the part is removed &
Teflon tape is wrapped on the threads properly & the part is then

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 refitted carefully.

12. REFERENCES:
1. Coulson & Richardson, “Chemical Engineering Vol-3” 4th ed., Asian Books
Pvt.Lt, ND, 1991, Page 233.

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