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.

O presente texto descreve um método experimental simples para comparar a eficiência de distribuidores de líquido empregados nas indústrias de tratamento de minérios em lavadores, classificadores e moinhos e nas indústrias de processos químicos. A técnica consiste basicamente em analisar a dispersão pelo desvio padrão da massa do líquido coletado em tubos verticais dispostos em arranjo quadrático colocados abaixo do distribuidor. Como exemplo de aplicação, empregouse para a coleta da massa de líquido uma unidade piloto, montada no Laboratório de Engenharia Química da Universidade Santa Cecília em Santos, com um banco de 21 tubos verticais de 52 mm de diâmetro interno e 800 mm de comprimento. Uma manta acrílica que não dispersa o líquido com 50 mm de espessura foi fixada entre o distribuidor e o banco de tubos para evitar respingos. Foram realizados ensaios com nove distribuidores do tipo espinha de peixe de 4 tubos paralelos cada, para uma coluna piloto com 400 mm de diâmetro. A literatura é discordante no que concerne aos parâmetros de projeto e eficiência destes distribuidores. Variaram-se o número (n) de orifícios (95, 127 e 159 furos/m2, 12, 16 e 20 furos por distribuidor) o diâmetro (d) dos orifícios (2, 3 e 4 mm) e as vazões de entrada indicadas por rotâmetro nos distribuidores (q) de 1,2; 1,4 e 1,6 m3/h. A melhor eficiência de espalhamento pelo menor desvio padrão (0,302) foi obtida com n de 159 furos/m2, d de 2 mm e q de 1,4 m3/h indicando as limitações dos parâmetros de projeto da literatura. A pressão (p), na entrada do distribuidor para esta condição, foi de apenas 0,51 kgf/cm2. A relação adimensional entre a área da seção do tubo de alimentação e a somatória da área dos furos foi de 5,81, a vazão volumétrica total por unidade de área da seção da coluna para esta melhor condição foi de 11,32 m3/(h.m2) e a velocidade média (v) em cada orifício foi de 6,31 m/s. Portanto, o método proposto permite comparar e quantificar a eficiência de distribuidores além de demonstrar a não validade de alguns parâmetros de projeto recomendados pela literatura. / The current text describes a simple experimental method in order to compare the efficiency of the liquid distributors applied at the ore treatment industries in washers, classifiers and mills as well as at the chemical processing industries. The technique basically consist of analyzing the dispersion through the standard deviation of the liquid mass which was collected in vertical pipes placed in a square way under the distributor. As an example of us usage, it has been applied a pilot scale for collecting the liquid mass, installed at the Santa Cecília Universitys Chemical Engineering Laboratory in Santos, with a setting of 21 vertical tubes measuring 52 mm in internal diameter and 800 mm in length. A 50 mm thick acrylic blanket was fixed between the distributor and the pipe setting in order to avoid splashes. Some experiments have been made with a ladder-tipe distributors containing 4 parallel tubes each, for a pilot column of 400 mm in diameter. The literature shows disagreement regarding the characteristics of the project and the efficiency of the distributors. The number of holes has varied (n) 95, 127 and 159 holes/m2; 12, 16 and 20 holes for distributor, the diameter of the holes (d) 2, 3 and 4 mm and the flow of entrance in the distributors (q) of 1,2; 1,4 and 1,6 m3/h. The best efficiency of splashing of the lowest deviation pattern (0,302) was achieved with n of 159 holes/m2, d of 2 mm and q of 1,4 m3/h showing the limitation of characteristics of the project literature. The pressure (p), for this condition in the distributor entrance, was only 0,51 kgf/cm2. The measuring relation between the area of the section of the feeding pipe and the addition of the area of the roles was 5,81, the total volume of the out flow for unit of the area of the column section for this better condition was 11,32 m3/(h m2) and the average speed (v), in each hole was 6,31 m/s. Finally, the indicated method permits the comparison and quantification of the efficiency of the distributors, besides showing that some of the project concepts are not valid and the literature does not recommend them.

O presente texto descreve um método experimental simples para comparar a eficiência de distribuidores de líquido empregados nas indústrias de tratamento de minérios em lavadores, classificadores e moinhos e nas indústrias de processos químicos. A técnica consiste basicamente em analisar a dispersão pelo desvio padrão da massa do líquido coletado em tubos verticais dispostos em arranjo quadrático colocados abaixo do distribuidor. Como exemplo de aplicação, empregouse para a coleta da massa de líquido uma unidade piloto, montada no Laboratório de Engenharia Química da Universidade Santa Cecília em Santos, com um banco de 21 tubos verticais de 52 mm de diâmetro interno e 800 mm de comprimento. Uma manta acrílica que não dispersa o líquido com 50 mm de espessura foi fixada entre o distribuidor e o banco de tubos para evitar respingos. Foram realizados ensaios com nove distribuidores do tipo espinha de peixe de 4 tubos paralelos cada, para uma coluna piloto com 400 mm de diâmetro. A literatura é discordante no que concerne aos parâmetros de projeto e eficiência destes distribuidores. Variaram-se o número (n) de orifícios (95, 127 e 159 furos/m2, 12, 16 e 20 furos por distribuidor) o diâmetro (d) dos orifícios (2, 3 e 4 mm) e as vazões de entrada indicadas por rotâmetro nos distribuidores (q) de 1,2; 1,4 e 1,6 m3/h. A melhor eficiência de espalhamento pelo menor desvio padrão (0,302) foi obtida com n de 159 furos/m2, d de 2 mm e q de 1,4 m3/h indicando as limitações dos parâmetros de projeto da literatura. A pressão (p), na entrada do distribuidor para esta condição, foi de apenas 0,51 kgf/cm2. A relação adimensional entre a área da seção do tubo de alimentação e a somatória da área dos furos foi de 5,81, a vazão volumétrica total por unidade de área da seção da coluna para esta melhor condição foi de 11,32 m3/(h.m2) e a velocidade média (v) em cada orifício foi de 6,31 m/s. Portanto, o método proposto permite comparar e quantificar a eficiência de distribuidores além de demonstrar a não validade de alguns parâmetros de projeto recomendados pela literatura. / The current text describes a simple experimental method in order to compare the efficiency of the liquid distributors applied at the ore treatment industries in washers, classifiers and mills as well as at the chemical processing industries. The technique basically consist of analyzing the dispersion through the standard deviation of the liquid mass which was collected in vertical pipes placed in a square way under the distributor. As an example of us usage, it has been applied a pilot scale for collecting the liquid mass, installed at the Santa Cecília Universitys Chemical Engineering Laboratory in Santos, with a setting of 21 vertical tubes measuring 52 mm in internal diameter and 800 mm in length. A 50 mm thick acrylic blanket was fixed between the distributor and the pipe setting in order to avoid splashes. Some experiments have been made with a ladder-tipe distributors containing 4 parallel tubes each, for a pilot column of 400 mm in diameter. The literature shows disagreement regarding the characteristics of the project and the efficiency of the distributors. The number of holes has varied (n) 95, 127 and 159 holes/m2; 12, 16 and 20 holes for distributor, the diameter of the holes (d) 2, 3 and 4 mm and the flow of entrance in the distributors (q) of 1,2; 1,4 and 1,6 m3/h. The best efficiency of splashing of the lowest deviation pattern (0,302) was achieved with n of 159 holes/m2, d of 2 mm and q of 1,4 m3/h showing the limitation of characteristics of the project literature. The pressure (p), for this condition in the distributor entrance, was only 0,51 kgf/cm2. The measuring relation between the area of the section of the feeding pipe and the addition of the area of the roles was 5,81, the total volume of the out flow for unit of the area of the column section for this better condition was 11,32 m3/(h m2) and the average speed (v), in each hole was 6,31 m/s. Finally, the indicated method permits the comparison and quantification of the efficiency of the distributors, besides showing that some of the project concepts are not valid and the literature does not recommend them.

Bei der Rektifikation werden heute zunehmend Füllkörperkolonnen mit geordneten Packungen eingesetzt. Die Maldistribution, ein bislang ungelöstes Problem in Füllkörperkolonnen, wirkt sich negativ auf die Stoffaustauschleistung aus. Zur Verringerung der Maldistribution wird zwischen den Packungssektionen mehrfach die Rücklaufflüssigkeit gesammelt und erneut gleichmäßig über den Kolonnenquerschnitt verteilt. Diese Neuverteilung realisieren Zwischenverteiler, die somit einen Großteil der Kolonnenhöhe beanspruchen und damit die Investitions- und Betriebskosten erheblich erhöhen. Hauptursache für die Bauhöhe der Zwischenverteiler ist der Wunsch nach einem vollständigen Konzentrationsausgleich vor der Neuverteilung. Um die Kolonnenhöhe zu verringern und dennoch die gleiche Trennleistung zu erreichen, mangelt es den Anlagenbauern bislang an einer praktikablen Lösung. Entgegen der bisherigen Lehrbuchmeinung wird in dieser Arbeit die Bedeutung des vollständigen Konzentrationsausgleich grundsätzlich in Frage gestellt. Es erfolgen deshalb theoretische und experimentelle Untersuchungen für ein besseres Verständnis der Neuverteilung der Rücklaufflüssigkeit und deren Auswirkung auf die Trennleistung. Durch Modifizierung des klassischen Zwei-Kolonnen-Modells gelingt es, den Einfluss der Maldistribution, der Dampfquervermischung und der hydraulisch gleichmäßigen Flüssigkeitsneuverteilung mit und ohne vollständigen Konzentrationsausgleich numerisch zu simulieren. Die Überprüfung der Simulationsmodelle erfolgt an einer Pilotkolonne mit einem inneren Durchmesser von 1 m. Die Kolonne ist mit Sulzer MellapakPlus 752.Y ausgerüstet und als Testgemisch dient trans-/cis-Dekalin. Im Ergebnis zeigt sich, dass vor allem der hydraulische Ausgleich erforderlich ist und es praktisch keinen Unterschied zwischen vollständigen und unvollständigen Konzentrationsausgleich bei sonst gleichen Betriebsbedingungen gibt. Überlegungen für deutlich flachere Verteilerkonstruktionen werden vorgestellt.

Bei der Rektifikation werden heute zunehmend Füllkörperkolonnen mit geordneten Packungen eingesetzt. Die Maldistribution, ein bislang ungelöstes Problem in Füllkörperkolonnen, wirkt sich negativ auf die Stoffaustauschleistung aus. Zur Verringerung der Maldistribution wird zwischen den Packungssektionen mehrfach die Rücklaufflüssigkeit gesammelt und erneut gleichmäßig über den Kolonnenquerschnitt verteilt. Diese Neuverteilung realisieren Zwischenverteiler, die somit einen Großteil der Kolonnenhöhe beanspruchen und damit die Investitions- und Betriebskosten erheblich erhöhen. Hauptursache für die Bauhöhe der Zwischenverteiler ist der Wunsch nach einem vollständigen Konzentrationsausgleich vor der Neuverteilung. Um die Kolonnenhöhe zu verringern und dennoch die gleiche Trennleistung zu erreichen, mangelt es den Anlagenbauern bislang an einer praktikablen Lösung. Entgegen der bisherigen Lehrbuchmeinung wird in dieser Arbeit die Bedeutung des vollständigen Konzentrationsausgleich grundsätzlich in Frage gestellt. Es erfolgen deshalb theoretische und experimentelle Untersuchungen für ein besseres Verständnis der Neuverteilung der Rücklaufflüssigkeit und deren Auswirkung auf die Trennleistung. Durch Modifizierung des klassischen Zwei-Kolonnen-Modells gelingt es, den Einfluss der Maldistribution, der Dampfquervermischung und der hydraulisch gleichmäßigen Flüssigkeitsneuverteilung mit und ohne vollständigen Konzentrationsausgleich numerisch zu simulieren. Die Überprüfung der Simulationsmodelle erfolgt an einer Pilotkolonne mit einem inneren Durchmesser von 1 m. Die Kolonne ist mit Sulzer MellapakPlus 752.Y ausgerüstet und als Testgemisch dient trans-/cis-Dekalin. Im Ergebnis zeigt sich, dass vor allem der hydraulische Ausgleich erforderlich ist und es praktisch keinen Unterschied zwischen vollständigen und unvollständigen Konzentrationsausgleich bei sonst gleichen Betriebsbedingungen gibt. Überlegungen für deutlich flachere Verteilerkonstruktionen werden vorgestellt.