Impact of Fluids Distribution System on Bubble Column Hydrodynamics

Abstract

The performance of ebullated bed hydroprocessors depends on the fluids distribution system and liquid recycle pan. Given that bubbles do not readily coalesce in the bed, the original bubble size distribution generated at the bubble cap distributor likely impacts buoyancy-based phase separation at the recycle pan. Gas entrained in the liquid recycle increases bed gas holdup at the expense of liquid holdup and product yield. The aim of this work was to investigate the impact of gas-liquid distribution system on resulting bubble properties and dynamics and incorporate a distributor sub-model into an existing fluid dynamics model of the industrial hydroprocessor. The size of initial bubbles formed in the plenum chamber was found to have negligible impact on phase holdups above the distributor. However, resulting bubble properties were found to depend on distributor geometry, distributor power dissipation and gas-liquid velocity ratio. In addition, a new set of scaling laws for gas-liquid distributors, based on dimensional analysis and similitude, was proposed. Geometric scaling was based on matching distributor fractional open area and ratios of critical dimensions. Dynamic similarity was based on matching three dimensionless groups and bubble coalescence behaviour. A bubble size distribution model was then developed. Both pressure and distributor were found to have an impact on individual bubble drag coefficients, as they both altered bubble size distribution. A novel drag model was thus also developed at industrially relevant conditions. Finally, a new gas-liquid distributor sub-model, including bubble size distribution and drag models previously developed, was incorporated into an overall fluid dynamics model of the hydroprocessor. The bubble size distribution model was also coupled with existing gas-liquid separation sub-model to better predict recycled gas and liquid fractions. A sensitivity analysis performed with the overall model revealed distributor configurations with potential of improving the processing capacity of the hydroprocessor.