Chemical Engineering Science 62 (2007) 7274 7281 www.elsevier.

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Analysis of local heat transfer and hydrodynamics in a bubble column using fast response probes
A.K. Jhawar, A. Prakash
Department of Chemical and Biochemical Engineering, The University of Western Ontario, London, Ont., Canada N6A 5B9 Received 17 April 2007; received in revised form 3 July 2007; accepted 12 August 2007 Available online 19 August 2007

Abstract A fast response probe is used to measure local heat transfer in a bubble column. It captured the variations in local heat transfer coefcients due to changes in local hydrodynamic conditions in radial and axial directions. These measurements have been used to identify ow regime transitions, variations in ow patterns and local hydrodynamic structure as obtained with different gas distributors and varying gas velocity. Standard deviations of pressure measurements obtained with a fast response probe have been compared with heat transfer coefcient uctuations for the rst time and the similarities and differences have been pointed out. Variations in average heat transfer coefcients and standard deviations in radial and axial directions point to different hydrodynamic conditions and are compared with literature studies. Relationships between local heat transfer measurements and hydrodynamic conditions are shown. 2007 Published by Elsevier Ltd.
Keywords: Local heat transfer; Bubble columns; Hydrodynamics; Flow regimes; Bubble; Pressure signals

1. Introduction Bubble columns with and without solids have found increasing number of applications in chemical, petrochemical, biochemical and environmental processes (Deckwer and Schumpe, 1993; Prakash et al., 1999, 2001; Dudukovi et al., 2002). The c main benets of these reactors include simple construction, easy operation, excellent temperature control, high heat and good mass transfer rates, on-line catalyst addition and withdrawal and good mixing of the phases by gas aeration only (Deckwer and Schumpe, 1993; Kluytmans et al., 2001; Li and Prakash, 2002; Li et al., 2003). However, proper design, scale-up and operation of these columns require detailed understanding of prevailing hydrodynamic conditions such as ow regime and proles of gas holdup, heat and mass transfer. Moreover, good understanding of local heat transfer proles and hydrodynamics can lead to optimum internals design and their location.

Corresponding author. Tel.: +1 519 661 2111x88528.

E-mail address: aprakas2@uwo.ca (A. Prakash). 0009-2509/$ - see front matter doi:10.1016/j.ces.2007.08.026 2007 Published by Elsevier Ltd.

Local heat transfer measurements can provide insights into ow patterns in bubble columns (Li and Prakash, 2002). In last two decades, effects of different variables on column hydrodynamics have been widely investigated (Hills, 1974; Khare and Joshi, 1990; Wilkinson et al., 1992; Krishna et al., 1997; Gandhi et al., 1999; Li and Prakash, 2000; Vial et al., 2000; Kluytmans et al., 2001; Ruicka et al., 2003). A few of these studies have also included effects of distributor design on the column hydrodynamics (Vial et al., 2001; Veera and Joshi, 1999; Zahradnk et al., 1997). Some studies have also reported heat transfer measurements in bubble columns (Li and Prakash, 1997; Li, 1998; Li et al., 2003; Luo et al., 1997; Saxena et al., 1990a,b, 1992). However, effects of distributor design on heat transfer have not been studied systematically. This study compares the effects of a coarse and a ne sparger on local heat transfer measured by a fast response probe and attempts to relate the measurements to column hydrodynamics. Both radial and axial variations of heat transfer coefcients have been presented. Heat transfer measurements have also been compared with the more commonly used pressure measurements method, for the rst time. Similarities and differences between the two methods are pointed out.

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2. Experimental Experiments were conducted in a Plexiglas column of 0.15 m internal diameter and height of 2.5 m (Fig. 1). The column was supported by rigid metallic structure to keep it vertical and minimize mechanical vibrations which might affect pressure and heat transfer signals. Two types of distributors were used to introduce oil free compressed air in the column: a sintered steel plate distributor of pore size 15 m and a coarse sparger which consisted of four arms. The sintered steel plate sparger was of 160 mm diameter and about 2 mm thick. The coarse sparger has two levels separated by a xed distance of 25 mm. The detailed design of the coarse sparger is explained elsewhere (Gandhi, 1997). Only lower level sparger which had ve (1.9 mm diameter) downward facing holes on each arm was used for this study. Oil free compressed air was used as a gas phase and tap water was used as the liquid phase. The gas ow rate was measured

using three calibrated sonic nozzles of different diameter (0.7, 1.5 and 2.5 mm). A measuring tape was provided on the column to note the liquid level and dispersion height. An air box of 0.3 m height was used with sintered steel plate distributor. The supercial gas velocity was varied from 0.03 to 0.35 m/s. Inlet air was maintained at 22 C using OMEGA (AHP-7562) inline air heater. The unaerated water height in the column was maintained at around 1.45 m. A pressure transducer (OMEGA Type PX541-7.5GI) was used to measure the pressure uctuations in bulk section (z = 0.81 m), as shown in Fig. 1. The pressure transducer was connected to a DC power supply and generated a voltage proportional to measured pressure. The response time of the pressure transducers was 2 ms and data were recorded for 105 s at a rate of 60 Hz. Instantaneous heat ux was measured using a micro-foil heat ux sensor (RdF, Model number 20453-1 G161). The sensor was ush mounted on the surface of a brass cylinder of 11 mm

Fig. 1. Schematic diagram of the experimental setup.

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outer diameter. A small cartridge heater (Chromalox, model number CIR-1012) was installed inside the brass cylinder. The AC power was supplied to the cartridge heater through a variac to regulate supplied power in the range of 2040 V. The detailed design of the heat ux probe is explained elsewhere (Li and Prakash, 1997; Li, 1998). Probe location could be changed both axially and radially. The temperature of the liquid phase was measured using two copper-constantan thermocouples (ANSI type T). These thermocouples were located at two radial locations: one at center and other close to the wall. Axial position of the thermocouple could be changed. The response time of micro-foil heat ux sensor was 20 ms and data were recorded for 180 s at a rate of 60 Hz. The probe generated microvolt signals, which were amplied to millivolts by a suitable amplication circuit using 12 V DC supply. The recorded signal was also corrected for baseline values obtained in the absence of any power supply to the cartridge heater. Average error or uncertainty due to this correction was estimated to be less than 8%. A minimum of two test runs were performed at each condition and average values are reported. For the heat ux sensor, the following equation can be derived for liquid lm heat transfer coefcient (Li and Prakash, 2001): 1 TS T b x = . hi q/A k (1)

Fig. 2. Variation in heat transfer coefcients with supercial gas velocity for ne and coarse sparger (z = 0.91 m).

The second term on the right-hand side of Eq. (1) is negligible compared to the rst term (< 1%) due to high conductivity (k) and small thickness ( x) of the thermal barrier lm. Therefore, instantaneous heat transfer coefcient could be determined by the measurement of heat ux and the difference between surface and bulk temperatures at a given time. The time-averaged heat transfer coefcient at a given location was obtained by averaging the instantaneous heat transfer data collected. havg = 1 N
N i=1

q/A . TS T b

(2)

Fig. 3. Variation in gas holdup with supercial gas velocity for ne and coarse sparger.

3. Results and discussion Fig. 2 compares the heat transfer coefcients obtained at the center and near the wall in the bulk section (z = 0.91 m) with the ne and coarse spargers. In the column center, the heat transfer coefcients obtained with the coarse sparger are higher than those with the ne sparger up to a gas velocity of about 0.125 m/s. For higher velocities the values are similar for the two spargers. The bubble column operates in the fully developed heterogeneous regime at these high velocities (Wilkinson et al., 1992; Zahradnk et al., 1997). In the heterogeneous regime the column hydrodynamics tend to become essentially independent of the effects of primary gas dispersion orice diameter and the character of bubble bed is primarily determined by the bulk liquid circulation (Joshi and Lali, 1984). It is also noted from Fig. 2 that for the ne sparger, difference between the two radial positions is initially low (for Vg < 0.05 m/s) but increases rapidly for higher gas velocities. These observations show a strong dependence of heat transfer on column hydrodynamics. The average gas holdups measured with the two spargers are compared in Fig. 3 as determined from the bed expansion. It can be seen that the gas holdup plot with the ne distributor clearly depicts three main ow regime identied in the literature (Lin et al., 2001; Vial et al., 2000; Zahradnk et al., 1997; Chen et al., 1994). These are bubble ow below gas velocity of 0.05 m/s, transition ow up to about 0.1 m/s and heterogeneous regime for higher gas velocities. For coarse sparger, it is evident that no homogeneous bubbling regime is generated. This supports the generally accepted view that for hole diameter greater than or equal to 1.6 mm the bubbly ow (homogeneous) regime is not generated and the gas holdup structure is similar to heterogeneous bubbling (Wilkinson et al., 1992; Zahradnk et al., 1997). The fully developed heterogeneous regime starts above the gas velocity of 0.125 m/s (Zahradnk et al., 1997). In this regime, the average gas holdup is not affected by the primary bubble size but is related to gross circulation patterns created by fast

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Fig. 5. Standard deviation of heat transfer coefcients obtained with ne and coarse sparger in bulk section. Fig. 4. Radial prole of heat transfer coefcients obtained with ne and coarse sparger (z = 0.91 m).

rising large bubbles (Vial et al., 2000; Lin et al., 2001). As observed from Fig. 2, the average heat transfer coefcients obtained with the two spargers come together above gas velocity of 0.125 m/sthe fully developed heterogeneous regime. Fig. 2 also shows that the heat transfer coefcients obtained near the wall are lower than in the central region for both spargers. For the ne sparger, the difference between the two regions increases rapidly with increasing gas velocity and becomes nearly constant for velocities above 0.15 m/s. For the coarse sparger, the differences in the two radial positions increase more slowly. The heat transfer coefcients near the wall for the coarse sparger are always higher than those with the ne sparger. This difference for the two spargers could be partially attributed to different bubble sizes in the region due to the two spargers. It was observed visually that the average bubble size in the wall region was signicantly smaller with the ne sparger even at high velocities. This indicates that the small bubble size continues to be a function of distributor design even with change in ow regime and the effect of distributor design is not completely lost. It is also observed from Fig. 2 that heat transfer coefcients at low gas velocities (< 0.05 m/s) are similar for the ne sparger in both regions indicating narrow bubble size distribution for these low velocities. Radial proles of heat transfer coefcients obtained with the two spargers are presented in Fig. 4. It can be observed that the prole is nearly at in the bubbly ow regime and becomes steeper with increasing gas velocities. These observations can be related to reported radial proles of gas holdups and liquid velocities in bubble columns (Vial et al., 2001; Veera and Joshi, 1999; Ueyama and Miyauchi, 1979; Hills, 1974). The steeper proles obtained with the ne sparger again show that the lower turbulence is caused by the smaller bubbles in the wall region. Although the average heat transfer coefcients plot provided a good indication of the onset of the fully developed heteroge-

neous regime, it could not indicate the beginning of the transition regime. A comparison of standard deviations of instantaneous heat transfer coefcients, presented in Fig. 5, showed that the values are lowest with the ne sparger at the center below gas velocity of 0.1 m/s and then cross the values obtained in the wall region for higher gas velocities. It can be noted that while the average heat transfer coefcients are higher in the center (Fig. 2), the standard deviations are lower below the gas velocity of 0.1 m/s. The higher standard deviations in the wall region can be attributed to chaotic verticalspiral ow motion of the transition regime as pointed out by Chen et al. (1994). For higher velocities larger bubbles begin to form and their larger associated wake causes high turbulence indicating the end of the transition regime. It can also be noted from Fig. 5 that changes in standard deviations with gas velocity are much smaller above gas velocity of 0.15 m/s for both spargers. This indicated that bubble size distribution has stabilized above this velocity and gross liquid circulation has been established. The differences in heat transfer coefcients in the distributor and bulk sections of the column are shown in Fig. 6 for the ne sparger. Unlike the bulk section, there is only small difference between the center and wall regions in the distributor zone. Moreover, the difference tends to decrease with increasing velocity. This indicates the existence of very different mixing patterns in the area compared to the bulk section. Smaller differences in heat transfer coefcients at different radial locations indicate more uniform mixing, although intensity is low as indicated by the lower heat transfer coefcients. Similar conclusions were reached by Li and Prakash (2002) using a coarse sparger in a larger diameter bubble column. A comparison of standard deviations of the measured heat transfer coefcients in the central region at the two axial locations gives an intersection around gas velocity of 0.1 m/s pointing to the end of rst transition regime (Fig. 7). It is also interesting to note that the standard deviations are higher in the distributor zone compared to bulk below the transition velocity. This could be attributed to lower homogeneity in the area compared to the bulk zone

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Fig. 6. Comparison of heat transfer coefcients for ne sparger in distributor (z = 0.025 m) and bulk (z = 0.91 m) sections.

Fig. 8. Standard deviation of pressure signal uctuations obtained with ne and coarse sparger (z = 0.81 m).

Fig. 7. Comparison of standard deviations of heat transfer coefcients obtained with the ne distributor in the distributor (z = 0.025 m) and bulk (z = 0.91 m) sections (r/R = 0).

Fig. 9. Comparison of standard deviations of heat transfer coefcients and pressure signal uctuations for ne sparger.

for these conditions. The standard deviations are essentially the same for higher velocities in the distributor zone but increase quickly in the bulk section again indicating the existence of very different mixing patterns in the two zones. The fast response pressure transducers used in this study also provided standard deviations of the pressure uctuation signals measured at the column wall. Fig. 8 compares the standard deviations obtained with the two distributors in the bulk section of the column. The plot for the ne sparger shows clear transitions at velocities near 0.1 and 0. 125 m/s, while the plot for the coarse sparger provides transition to the fully developed heterogeneous regime. It is observed that the standard deviations are higher for the coarse sparger than the ne sparger in both homogeneous and transition regimes and in heterogeneous they come closer. The high standard deviations obtained with

coarse sparger can be related to larger bubbles generated even at lower velocities from the coarse sparger. A comparison of standard deviations obtained with the two methods used in this study is presented in Fig. 9 for the case of ne distributor. It can be seen that intersection between standard deviations for wall and central region heat transfer signals corresponds well with the transition point obtained with pressure uctuations. Also in the fully developed heterogeneous regime, the variations in standard deviations with gas velocity are small for central region heat transfer coefcients. Earlier a similarity between central and wall region heat transfer coefcients obtained at low supercial gas velocity using ne sparger provided the presence of homogeneous regime in the bubble column (Fig. 2). So the fast response probe used to measure local heat transfer in this study can be used to identify ow regime transitions as well. The instantaneous heat transfer coefcient was analyzed for skewness ( ), which is a measure of asymmetry of the

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Table 1 Comparison of frequency distribution of average heat transfer coefcient for ne and coarse sparger in bulk section of the column (VG = 0.21 m/s)
havg (kW/m2 C) Frequency Fine sparger r/R = 0 0.5 2 6 9 12 15 18 19 20 0 168 7844 1907 581 171 104 4 0 r/R = 0.624 0 1054 9013 616 116 10 0 0 0 Coarse sparger r/R = 0 0 136 7223 2036 811 334 160 30 19 r/R = 0.624 1 242 8878 1327 277 66 0 0 0

Fig. 10. Comparison of skewness of heat transfer coefcients and pressure signal uctuations for ne and coarse sparger in the bulk section.

probability distribution of a real-valued random variable. A skewed distribution occurs when few values are much higher or lower than the typical values found in data set. If the extreme values are concentrated on the right of the curve, the distribution is said to be positively skewed. If the extreme values are concentrated on the left of the curve, the distribution is said to be negatively skewed. Skewness is dened as = N (N 1)(N 2) xi x
3

(3)

where N is the number of data points, is the standard deviation and x is the mean data value. If the data are symmetrically distributed about the mean, the skewness will be zero. Fig. 10 presents the skewness of instantaneous heat transfer data obtained at two radial locations (r/R = 0 and 0.624) in the bulk section and pressure uctuation data obtained, using both spargers. It can be seen that the heat transfer coefcient data are positively skewed at all the gas velocities and highest values are obtained at the center for coarse sparger. The values are much lower for the wall region for both distributors with slightly higher values for the coarse sparger. Moreover, variation in wall region is small with increasing gas velocity. For the ne sparger, the values for the two radial locations are close below gas velocity of 0.1 m/s but central region values increase rapidly for higher velocities. However, they remain lower than coarse sparger values which are signicantly higher for all velocities indicating larger fraction of larger bubbles in the dispersion. A comparison of frequency distribution of heat transfer data obtained at the center and the wall for both spargers in the bulk section is presented in Table 1. It can be seen that at the column center, frequency of higher value heat transfer data is higher for the coarse sparger. This difference can be attributed to the existence of different bubble size distribution with the two distributors. Bouai et al. (2001) have shown that the bubble size distribution obtained with perforated plate is more widely spread than that obtained with the ne sparger. It

Fig. 11. Variation in heat transfer coefcients with average bubble rise velocity for ne and coarse spargers (z = 0.91 m, r/R = 0).

can also be seen from Fig. 10 that the skewness of pressure signals is very similar for the two spargers and it cannot provide the kind of distinction obtained with the local heat transfer data. The values are close to zero indicating symmetric distribution about mean of the uctuations related to momentum exchange in the bubble column. A few negative values at low gas velocities could be due to measurement accuracy at these conditions. A plot of average bubble rise velocity (Vg / g ) and average heat transfer coefcients at the center shows existence of two clear regions (Fig. 11). The data points in the rst region (Vg / g 0.3 m/s and Vg < 0.09 m/s) belong to the homogeneous and intermediate regime obtained with the ne sparger. All the data points obtained with the coarse sparger and remainder of data points obtained with the ne sparger lie in the second regionthe heterogeneous regime (Vg / g > 0.3 m/s). Following linear relationships were obtained for the data sets in the two regions. Vg / g 0.3 m/s hc,avg = 8.65 VG
G

+ 1.32,

R 2 = 0.99,

(4)

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g

Vg /

> 0.3 m/s VG

G

hc,avg = 2.0

+ 3.3,

R 2 = 0.97.

(5)

It can be seen that the slope in Eq. (4) is much higher than that in Eq. (5). This could be attributed to faster growing bubble size and their number passing through the central region. These bubbles with their associated wake move through the column center inducing higher level of turbulence in the region and creating turbulence anisotropy in the column. It was observed in Fig. 5 that standard deviation of heat transfer coefcient increases at the highest rate with the ne sparger in this region, an indication of increasing turbulence. In the heterogeneous regime, the slope decreases signicantly as the stable bubble size is approached and bubble growth rate slows down. However, it can also be noted from this gure that the average bubble rise velocity rises at a faster rate in the heterogeneous region which is a result of well-known acceleration effect caused by the wake of preceding bubbles. This indicates a different heat transfer mechanism dominating in the region. In a future work, data from different diameter columns and other operating conditions will be combined to present appropriate correlations and heat transfer models. The radial prole data obtained in the heterogeneous regime allowed following correlation to estimate heat transfer coefcient at different radial locations knowing the value at the center. hc h(r) = hc n1 n r R
n

uctuations is also presented for the rst time. Empirical correlations to estimate local average heat transfer coefcient are proposed based on the data of this study. In a future study, the authors plan to present more general correlations and models based on additional testing. Notation A Cp Dc h k n N Nu Pr PS q r R Re T VG x z heat transfer area, m2 heat capacity, J/kg K diameter of the column, m heat transfer coefcient, kW/m2 C thermal conductivity, W/m K to exponent in Eq. (6) number of data points hD c Nusselt number kl Cp,l l Prandtl number kl pressure signal uctuations, V heat ow rate, kW radial location, m radius of the column, m l Vg D c Reynolds number temperature, C supercial gas velocity, m/s thickness of thermal barrier, m axial location from the bottom of the column, m
l

(6)

The optimum value of n was determined to be 1.4 for all gas velocities with the coarse sparger and for velocities in the transition regime with the ne spargerpredictions within 5%. The average error at higher gas velocities (> 0.125 m/s) with ne sparger increased to more than 15% which can be attributed to different radial proles obtained with the two spargers (Fig. 4). For these conditions a higher value of n (=2.05) reduced the average error to less than 9%. This again points to different holdup proles for the two spargers. Eq. (6) with n of 1.4 also well predicted (within 10%) the average heat transfer coefcient at other radial locations knowing the heat transfer coefcient at the column center for data of Li and Prakash (2001). These authors used a coarse sparger in a larger diameter (0.28 m) column. 4. Concluding remarks A comparison of local heat transfer coefcient variations in a bubble column using a ne and a coarse gas distributor is presented for the rst time. The inuences of ow regime and associated column hydrodynamics are discussed. It is shown that the measurements of local heat transfer coefcients by the fast response probe of this study can be utilized to identify ow regime transitions in the column. Such a probe can be used to investigate effects of internals design on local hydrodynamics and heat transfer. A direct comparison of ow regime identication based on pressure uctuation and heat transfer

Greek letters
G

skewness average gas holdup viscosity of water, Pa s density of water, kg/m3 standard deviation

Subscripts avg b c G i l S SD w References

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average bulk center gas instantaneous liquid surface standard deviation wall

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