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Abstract
Gas–liquid %ow in packed towers is commonly encountered in the chemical and processing industry. A continuum model is
developed based on the volume-and-time averaging of multiphase %ows in isotropic rigid porous media=packed columns. Closures
are presented for the evaluations of the extra surface=intrinsic phase integral terms. Both inertia and inter-phase interactions are
retained in the volume averaged (Navier–Stokes) equations. These governing equations are solved for fully-developed axi-symmetric
single and gas–liquid two phase %ows in highly porous packed towers. It is found that the dispersion term is present in the
continuity equation as well as the momentum equations. Numerical simulations with the models show that the volume-and-time
averaged equations can predict the velocity, phase hold-up and pressure drop quite well for up to the loading point for gas–liquid
counter-current %ows. ? 2001 Elsevier Science Ltd. All rights reserved.
Keywords: Packed tower; Multiphase %ow; Volume-and-time averaging; Counter-current %ow; Velocity distribution; Phase hold-up
0009-2509/01/$ - see front matter ? 2001 Elsevier Science Ltd. All rights reserved.
PII: S 0 0 0 9 - 2 5 0 9 ( 0 1 ) 0 0 2 3 2 - 9
5946 S. Liu / Chemical Engineering Science 56 (2001) 5945–5953
porosity as well. The packing factor is normally supplied In this case, the porous medium will be treated as a con-
by manufactures for each speciEc random packings. Be- tinuous medium and thus no internal porous matrix con-
cause the expression is usually used for dry gas %ow Eguration and %ow patterns need to be speciEed.
through packed beds, a subscript G was used in Eq. (2). The volume-and-time averaged continuity equation is
A collection of data for the packing factor is also avail- given by
able in textbooks, for example, Trebal (1980).
@(i hi )
Richards (1931) and Muskat (1937) intuitively ex- + · (i hi ũ i ) − · (i ũ di ) = 0: (6)
tended the Darcy’s law to multiphase %ows. In their ex- @t
tension, the equation remains the same for each phase but Eq. (6) is similar to the traditional phase balance (or con-
allowing the %uid properties as well as the permeability tinuity) equation except for the dispersion %ux ũ di . For
to diJer. That is, multi-phase %ow with at least one non-continuous phase,
there exists a dispersion %ux for each phase. Because of
ki
ṽi = − ( pi − i g̃); (3) the diJerence in mobility (or resistance to %ow) for each
i component, the relative distributions of the diJerent com-
ponents will be diJerent at diJerent spatial locations. The
where the subscript i denotes the ith %uid phase, k is the
diJerence in the relative distribution (or concentration)
permeability and is the dynamic viscosity. Although
will give rise to “hydrodynamic diJusion” or dispersion.
widely used for %ow in soils and sandstones, Eq. (3) lacks
However, if all the phases are continuous, the phase dis-
three key features (Liu, 1999b): namely, inertial eJects;
persion is diminished.
diJusion eJects and the inter-phase interactions (Dullien,
Because of the dispersion, one may get a false sense
1992). These defects make Eq. (3) inapplicable to the
that the mass is not conserved. One should note that the
gas–liquid %ows in packed towers. In this paper, we shall
velocities are not volumetric transport %uxes in Eq. (6).
apply the volume-and-time averaging principles to derive
They are convection velocities for the respective phases.
a governing equation in packed towers.
There are two components in the transport %ux: convec-
tion and dispersion. Eq. (6) is a mass balance equation.
The mass transport %ux is given by
2. Volume-and-time averaged Navier–Stokes
equations for multiphase ows in porous media m̃i = i (hi ũ i − ũ di ); (7)
Although there are no diJerences between the intrinsic The above averaged Navier–Stokes equation is similar
phase averaged value and its corresponding local value to the averaged heat and mass transfer equations.
for (continuous) %ow in free space, the superscript ∗ in
the above equations is used to distinguish them from the
averaged quantities in a porous medium. 3. Volume-and-time averaged Navier–Stokes
For %ow through porous media, Eqs. (4) and (5) are equations and closure models for gas–liquid ows in
still applicable within each continuous %uid phase. How- packed towers
ever, solutions of these equations become formidable due
to the complex and often unknown conEgurations of the For gas–liquid %ows in packed towers, the following
free voids and the %ow straits of each %uid phase. To assumptions can be made to establish a simple mathe-
add to the complexity, at a given location, the occu- matical model: (1) the packing medium is isotropic and
pant phase can be diJerent at diJerent times. Therefore, random, (2) liquid wets the solid surface and there are
volume-and-time averaging is necessary in order for a negligible contacts between the gas and the solid, (3)
meaningful solution to be reached in most applications. there is no surface force eJect on the %ow behavior. In
S. Liu / Chemical Engineering Science 56 (2001) 5945–5953 5947
particular, liquid is not foaming. With this assumption, tion can still be recognized. Liu and Long (2000) gave
the applicability of the following analyses will be limited
to %ows below loading point, (4) both gas phase and ∗ + b 1 − b
= = b + Er [(1 − 0:3pd )
liquid phase are incompressible. This assumption is valid 2 2
strictly if the system is isothermal and isobaric, (5) the 2 R−r
%uids are Newtonian and the viscosity remains constant × cos + 0:3p d ; (11)
1 + 1:6 Er 2 pd d
in the tower.
where ∗ is the local azimuthal averaged porosity, pd is
3.1. The governing equations the period of oscillation normalized by the characteristic
(or nominal) particle size d; Er is the exponential decay-
The continuity equation for both liquid and gas phases ing function and b is the bulk porosity or the porosity
are given by Eq. (6) and the momentum equations can in an unbounded packing. For spheres of uniform size
be simpliEed from Eq. (8). ds ; pd = 0:94 and d = ds . For cylinders of equal height
and diameter such as Pall-rings, d is the
√ normal size (di-
@L hL ũ L hL
+ · (L hL ũ L ũ L ) + ( p − L g̃) ameter or height) and pd = 0:94(2 + 2)=3. The expo-
@t nential decaying function is given by
− · L [ hL ũ L + ( hL ũ L )T ] + L FL ũ L 3=4
R−r
− · [K LG · (L hL ũ L − G hG ũ G )] Er = exp −1:2pd : (12)
d
− · (L K L · hL ũ L ) + G FLG (ũ L − ũ G ) = 0 (9)
One can note that Eq. (11) is inadequate for the center
and region as the convenient condition: d=dr |r=0 = 0 may not
hold. The modiEed equation that satisfy the convenient
@G hG ũ G hG
+ · (G hG ũ G ũ G ) + ( p − G g̃) condition is given by
@t
∗ + b 1 − b
− · G [ hG ũ G + ( hG ũ G )T ] = = b + Er [(1 − 0:3pd )
2 2
− · [K LG · (G hG ũ G − L hL ũ L )]
2 R−r
× cos + 0:3pd ; (13)
+ G FLG (ũ G − ũ L ) = 0; (10) a + 1:6 Er 2 pd d
where the velocities, ũ i ’s, are “interstitial” convection. where a is a constant depending on the ratio of the par-
The transport velocities can be deEned similar to Eq. (7). ticle size to column size.
The velocities, hold-ups and pressure can be obtained by 3=4
solving Eqs. (6), (9) and (10) simultaneously together 2R R
a = − 1:6 exp −2:4pd
with no-slip conditions for both the gas and liquid phases n pd d d
on the column wall. However, this requires the complete
description of all the parameters involved. and
2 R
3.2. Closure model parameters n = int : (14)
1 + 1:6 exp[ − 2:4pd (R=d)3=4 ] pd d
In total, there are six parameters in the volume-and-time
averaged Eqs. (6), (9) and (10). These parameters 3.2.2. The shear factor for saturated single phase 4ow
are porosity, shear factors, interaction shear factor or The shear factor for saturated single phase %ow has
inter-phase interaction factor, phase dispersion %ux, mo- been reviewed by Liu and Masliyah (1996). The full im-
mentum dispersion coeOcient tensor and interaction plementation with porosity variations is given by Liu and
dispersion coeOcient tensor. These parameters need to Masliyah (1999). The shear factor, or %uid–solid matrix
be deEned (modeled or measured) before one can ap- interaction term, is given by
ply the volume-and-time averaged equations to simulate
%ows in packed towers. + b
F(ds ; ; |ũ|) = F0 ds ;
2
3.2.1. Porosity Re2
As an averaged quantity, short range variations (on + F1 (ds ; ) (Re − 3); (15)
Re2 + 36
or shorter than the particle scale) need not be consid-
ered. The averaging approach actively smoothes out where subscript 0 denotes for creeping %ow contribution
short-range local variations. However, long range varia- and I denotes for inertial contribution. Re is the %ow
5948 S. Liu / Chemical Engineering Science 56 (2001) 5945–5953
Reynolds number which is deEned as, Assuming the liquid phase is %owing along the surface
of the porous matrix, one obtains
Kinetic energy of %ow
Re = 24 hL 1 dp
Channel diameter ×Pressure drop FL0 = − − gx ; (25)
L |ũ L | dx L∞
(1=2)u2
e ds |ũ|
= 24
= 2 ; (16) where the subscript L∞ denotes “single” liquid phase
dp
de − d x − gx
∞ Elled in the channels formed by the porous matrix. Since
the liquid phase is covering all the solid surfaces, the void
where ue is the equivalent velocity of %uid in the pas- ratio is exactly the porosity, and the pressure drop can
sage, de is the equivalent hydraulic passage diameter and be related to the %ow velocity in a passage through
the subscript ∞ denotes unidirectional negligible inertial
%ow in the channel. dp 16k1 ueL
− − gx = L ; (26)
dx L∞ de deL
|ũ| |ũ|
ue = = (17) therefore,
A & 1=6
and 18(1 − hL )hL1=3
FL0 = : (27)
11=3 d2s
4 2ds
de = = ; (18) Similar to the shear factor for single phase saturated %ow,
ap 3(1 − )
the liquid phase shear factor is given by
where A is the eJective area ratio of the void space, & is
0:363 1 1=2
the tortuosity of the passage and ap is the speciEc surface FL = FL0 0:637 + + 0:048 + 0:46(eL
area of the bed. s'L s'L
Using the model of Liu and Masliyah (1999), the shear
ReL2
factors are deEned as × (ReL − 3) ; (28)
ReL2 + 36
18(1 − ) 0:363
F0 (ds ; ) = 10=3 2 0:637 + ; (19) where the Reynolds number is deEned similar to saturated
ds s' single phase %ow
18(1 − ) 1 (1=2) u2
FI (ds ; ) = 0:048 10=3 2 + 0:46(e1=2 ; (20) ReL = 24
L eL
ds s' Qp
deL − L − gx
L∞
where (e is the passage curvature ratio,
L ds |ũ L |
(e = 1 − 1=2 (21) = 5=3 hL1=3 : (29)
L
and s' is the shape factor which is deEned as Because of the tortuorous voids, the liquid phase tends to
move with a straight and uniform pathway when possible.
passage length
s' = : (22) We propose a compromise such that
passage diameter 1=3
1 − hL
The shape factor s' can be found from the relationship s'L = s' ; (30)
1 − hL
of dry pressure drop and FI () for the single gas phase
%ow. The relationship is given by, and
1=3
1 1 − hL
CD G UG2 = G FI (ds ; ∗ ) Re|ũ G |: (23) (eG = (1 − 1=2 ): (31)
2 1 − hL
3.2.3. Shear factor for the liquid phase This treatment should allow us to model %ows whereby
For multi-phase %ows, only Attou, Boyer, and Fer- the liquid phase is not only strictly %owing on the solid
schneider (1999) and Long and Liu (2000) attempted a surface. Because there is negligible solid matrix–gas
shear factor model. These two papers treat the shear fac- phase contact, the shear factor of the gas phase is negli-
tors in a very similar manner except diJerent model bases gible.
were used. In this paper, an extension of the model shown
in Section 3.2.2 will be presented for its suitability to 3.2.4. The interaction shear factor between gas phase
packed beds of high performance random packings. The and liquid phase
eJective velocity in the passage for the liquid %ow is Since we assume that the gas phase is the non-wetting
phase, the gas–solid interaction is negligible, that is,
|hL ũ L | |ũ L | FG = 0 and K G = 0. The interface between the two phases
ueL = = hL1=3 : (24)
AL &L 1=2 is equivalent to the solid surface for saturated single
S. Liu / Chemical Engineering Science 56 (2001) 5945–5953 5949
phase %ow. Similar to the liquid shear factor, with the solid matrix. The liquid completely wets the
18(1 − hG ) solid matrix and therefore the liquid dispersion can be
FG0 = (32) treated in the same manner as the single phase saturated
h23=6
G dsG
2
%ow. The liquid phase dispersion tensor for an isotropic
and medium is known to be of the following form
0:363 1 1=2
)L 0 0 )L 0 0
FGL = FG0 0:637 + + 0:048 + 0:46(eG
s'G s'G K L = KLrr 0 1 0 = ds DT |ũ L | 0 1 0 ; (39)
0 0 1 0 0 1
ReG2
× (Re G − 3) ; (33)
ReG2 + 36 where DT is the normalized transverse dispersion coef-
Ecient and )L is the normalized longitudinal dispersion
where s'G is the shape fact for the gas phase, (eG is factor. For packed beds of spheres
the passage curvature ratio for the gas phase and dsG is
the eJective porous matrix grain size for the gas phase DT = 10:711=3 (1 − )2=3 (1 − 0:75 Er): (40)
%ow
Here the exponential decay function is introduced into
(1 − hG )1=3 the dispersion coeOcient because of the insuOcient av-
dsG = ds : (34)
(1 − )1=3 eraging to be used for the porosity near the column
wall.
Therefore, the low %ow rate limit interface shear factor
is given by
3.2.6. The interaction dispersion coe5cient tensor
18(1 − hG )1=3 (1 − )2=3 The gas phase is completely surrounded by the liq-
FG0 = : (35)
h23=6
G ds
2 uid phase. The dispersion due to the interaction between
the gas and the liquid phases can therefore be treated
Using the same deEnition as Eq. (16) and noting the as the gas phase is %owing through a Ectitious porous
porous matrix grain size for the gas phase and interaction matrix, the solids coated with a layer of mobile liquid.
with the liquid phase at the boundary, the gas Reynolds That is
number is given by
1=3 √
)L 0 0
1 − hG ds |G hG ũ G − G L hL ũ L |
ReG = hG : K GL = KGLrr 0 1 0
1− G 0 0 1
(36)
1=3 )L 0 0
Similar to the shape factor and curvature related terms 1 − hG
for the liquid phase shear factor, the passage for the gas = ds DT |ũ G − ũ L | 0 1 0 (41)
1−
phase %ow is not rigid and therefore the modiEcations 0 0 1
of these terms must allow for the frequent pulsiEed %ow
and
pattern at the constrictions
h = DT = 10:7h11=3 2=3
G (1 − hG ) (1 − 0:75 Er); (42)
1 − hG G
s'G = s' (37)
1 − hG which is the same as that for saturated single phase %ow
with porosity replaced by the holdup.
and
hG =
1 − hG
(eG = (1 − 1=2 ): (38) 4. Numerical solutions
1 − hG
The closure model is introduced based on the promise We consider here fully developed two phase %ows in
that the liquid phase %ows along the solid surface and packed columns. The column is circular cylindrical and
forming an internal connected void in the passage pro- the %ows are axi-symmetrical. Only one non-zero aver-
portional to the void in the porous matrix. ModiEca- aged velocity component exists: the axial %ow velocity.
tions are subsequently made to account for the %exi- The cylindrical coordinate system is used with the axial
ble liquid Elm and the alternating %ow pattern at the (x-) axis pointing upwards (Fig. 1). All the Eeld variables
constrictions. are dependent only on the radial coordinate.
The continuity equations for the liquid and the gas
3.2.5. The liquid dispersion tensor phase are obtained from Eq. (6). We treat the case here the
The liquid dispersion is the dispersion of liquid phase bed porosity is high and pores are large. Liquid not only
Eeld variables due to the interaction of the liquid phase %ow alongside the solid surface, but forms droplets as
5950 S. Liu / Chemical Engineering Science 56 (2001) 5945–5953
hG dp G d dhG uG
− G g − r
dx r dr dr
1 d d(G hG uG − L hL uL )
Fig. 1. A schematic of the reference system for a packed tower. − rKGLrr
r dr dr
+ G FGL (uG − uL ) = 0; (48)
well. Therefore, there exists a dispersion %ux in the radial where uL and uG are the phase intrinsic axial %ow veloc-
direction due to the gradient of stress on the liquid=gas ities or the gas and the liquid phase, respectively.
phases similar to particulate dispersion in liquids (Liu, A visual Basic program has been developed to solve
1999a). Thus, we have the volume-and-time averaged Eqs. (43) – (48) based
on central diJerence method. The boundary conditions
L hL − G hG used are no slip conditions on the packed column wall.
FI = constant; i:e:; not a function of
The program was running under the Excel environment.
spatial locations; (43) Some of the numerical simulations are presented in
Figs. 2–5.
R Fig. 2 shows the computed velocity distribution for
L
L= 2rhL uL dr; (44) a saturated single phase %ow through a paced bed
R2 0
of spheres. One can observe that the current predic-
R tion agrees with the experimental data of Kufner and
G Hofmann (1990) reasonably well. The locations of the
G= 2rhG uG dr; (45)
R2 0 peaks and troughs in the velocity proEle agreed quite
well because of the treatment imposed by Eqs. (13)
hL + hG = (46) and (14). The diJerence in absolute values is due to
the fact that the experimental data is taken a few mm
and the momentum Eqs. (9) and (10), are reduced to above the actual packings—the peak and trough values
have been greatly dampened. The oscillation (appear-
hL dp ance of peaks and troughs) in velocity proEle is due to
− L g + L FL uL + G FGL (uL − uG )
dx the porosity variation in the radial direction. Therefore,
L d dhL uL 1 d d(L hL uL − G hG uG ) the strength of the current model is that it is capable
− r − rKGLrr of predicting the %ow behaviors for beds packed with
r dr dr r dr dr
large particles. In this case, only two particles can be
1 d dhL uL packed on the column radius and the predictions are still
− rL KLrr = 0; (47)
r dr dr reliable.
S. Liu / Chemical Engineering Science 56 (2001) 5945–5953 5951
Fig. 4. Pressure drop and liquid hold-up variation with liquid load
for air–water %ows in a column of 0:3 m in diameter packed with
50 mm plastic Nor-PacJ rings.
Fig. 5. Liquid velocity distributions for gas–liquid %ows in a column of 0:5 m in diameter and packed with random packings 3 m deep: (a)
and (b) 25 mm plastic Pallrings; (c) 50 mm plastics Pallrings; and (d) 38 mm ceramic Intalox saddles. The dot–dot–dashed lines are piece-wise
averaged experimental data from Kouri and Sohlo (1996).