Problem
The client had designed a new type of continuous reactor for a liquid-liquid-gas reaction. The client requested that BHRSolutions carry out experimental modeling work to assist them in:

• Understanding and quantifying the operation of the new reactor
• Comparing operation of new reactor to old reactor
• Optimizing new reactor

Objective
Plan and carry out a series of experimental studies to assist in design and optimization of a liquid-liquid-gas reactor.

Approach
The process was scaled down to operate in a 0.30m diameter H=3T vessel fitted with 4 impellers. BHRSolutions worked closely with the client to study the current design and the effect of reactor modifications on:

• Gas dispersion
• Gassed power draw
• Liquid phase residence time
• kLa
• Gas hold up in both two phase (gas-liquid) and three phase (liquid-liquid-gas) operation.
  

The Model
The process was modelled by using air and water and an organic liquid. Typical modifications studied included the effects of:

• Impeller type
• Gas feed position
• Gas flow rate
• Power input
• Droplet and bubble sizes

Results
The results indicated that the new reactor design was suitable for the process and some scope for optimization of 3-phase mixing still existed. Full details of the test results and analysis were provided to the client with video footage of the test work.

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