Microsoft Word - Document1



SUMMARY OF CREL MAIN ACTIVITIES

CREL research activities, achievements and funding during the period from July 1, 2007 through June 30, 2008, are briefly summarized below. Results of contract research work for individual companies are not reported here.

MRE RESEARCH ACTIVITIES

In general, research activities in CREL related to the MRE Project continued on various reactor types and topics related to multiphase reaction engineering in energy, chemicals and environmental processes (e.g., clean and alternative fuels, energy/bioenergy, chemical, benign processes, environmentally beneficial catalytic processes, preparation of new materials, etc.).

I. Multiphase reactors and processes: Experimental and modeling

The following types of multiphase reactors have been studied for the processes mentioned above:

|Bubble and slurry bubble columns |Packed beds |

|Fluidized beds |Stirred reactors |

|Circulating fluidized beds |Processes in mini and micro reactors |

|Spouted beds |Aerosol / particulate reactors |

|Trickle beds |Bioreactors and bioprocesses |

|Structures beds | |

The broad spectrum of CREL research activities over the years on chemicals, energy and environmental processes is schematically presented in Figure 3. The underlying theme of all our research is the improved understanding and quantification of transport-kinetic interactions in multiphase reaction systems using experimentation, modeling, and CFD. We are convinced that this knowledge will lead to safer, faster, more energy efficient and economical reactor selection, scale-up and design, environmental benign processes, and improved reactor control. In this annual report we summarize and highlight the research activities conducted during 2007/2008.

In addition, CREL is a core partner in the National Science Foundation (NSF) Engineering Research Center (ERC) for Environmentally Beneficial Catalysis Center (CEBC).

As mentioned earlier, the following are the general key areas which represent the pool for MRE research projects. These topics are investigated, as needed, in close interaction and collaboration with universities, national laboratories, and companies around the world.

i) Quantification of flow fields, in gas-liquid, liquid-solid, gas-solid, gas-liquid-solid systems in various reactor types via our unique radioactive particle tracking (RPT) and gamma ray computed tomography (CT) for measurement of instantaneous velocities, turbulence and backmixing parameters, time averaged circulation patterns voidage (holdup) distribution and other parameters. These data are not available by other means and can be used for scale up, design and model validation. This includes further development of our novel experimental techniques (RPT-CT) and other tools (optical probes, gas and liquid tracer techniques, heat transfer probes, mass transfer techniques, pressure fluctuation and pressure drop via differential pressure transducers, CCD camera, etc.) for measurement of flow, mixing, density profiles and transport in multiphase systems. No other laboratory in the world has this RPT-CT combination that provides the capabilities for studying systems with large volume fraction of the dispersed phase i.e. systems that we call opaque. Recently, progress has been made under DOE funding for anaerobic digester (Professor M. Al-Dahhan) to advance (Vesvikar, 2006) CARPT technique from single particle tracking to multiple radioactive particle tracking (MRPT) and CT from single γ-ray source to dual γ-ray source (DSCT) (Varma, 2008) where the density distribution of three moving phases can be measured simultaneously.

ii) Quantification of the reaction rate and kinetics, and evaluation and characterization of the existing, new or novel catalysts that are either in use in the existing processes and technologies or are developed for new and/or improved processes and technologies.

iii) Quantification of the impact of integrating the transport (hydrodynamics/momentum, mass and heat) and kinetics (chemistry/biology/electrochemistry) on the processes performance (i.e., conversion, selectivity, efficiency, safety, pollution generation, energy efficiency, etc.). Minireactors facilities made from Hastalloy C and titanium for oxidation, aklylation and other reaction processes equipped with IR probe (300 ml and 25 ml autoclave stirred reactors, 5 ml and 50 ml packed beds) have been developed and implemented.

iv) Development of advanced models for various multiphase reactor types (e.g., bubble and slurry columns, trickle beds, packed beds, stirred tanks, risers, fluidized beds, etc.) that can be coupled with client’s proprietary kinetics for improved design, scale up, operation or troubleshooting of commercial and pilot plant reactors. This includes using first principles in the development of hydrodynamic and reactor models, integrating transport, hydrodynamics and kinetics and verifying such models with carefully planned experiments.

v) Validation of CFD codes by RPT-CT and other techniques in various multiphase reactor types.

vi) Development of environmentally benign process technologies (e.g. clean alternative/renewable fuels and chemicals, hydrocarbon oxidation, solid acid alkylations, hydrogenations, hydroformulation and others).

vii) Development of new concepts and reactor technology for biomass conversion to fuels and chemicals, bioprocessing, wastes treatment, carbon dioxide capture, etc.

viii) Providing access to our new process concepts and ideas, facilities and expertise for potential joint projects.

ix) Inventing and investigating novel reactor types for application to energy, environmental, chemical, fuel, biochemical and material processes.

[pic]

FIGURE 3: Schematic Representation of MRE-CREL Activities Over the Years on Energy, Chemicals and Environmental Processes

II. PREPARATION OF NEW MATERIALS

In preparation of new materials we focus on the problems that could profit the most from implementation of reaction engineering principles in handling transport-kinetic interactions. Our goal is the implementation of reaction engineering in such processes in order to speed up scale-up and technology transfer to manufacturing. Our past experiences include work with:

• semiconductor silicon

• high performance composites

• microcapsules and biomaterials

Recently, CREL (Professors P.A. Ramachandran and M.P. Dudukovic) is working with MEMC (Dr. M. Kulkarni) to advance the fluidized bed technology for the growth of silicon particles. Past accomplishments include a model for manufacture of carbon fibers, in collaboration with our Materials Research Laboratory (MRL), and development of a new encapsulating material for time release systems with the model describing such release (in collaboration with our Biological Transport Laboratory (BTL)).

• In the semiconductor silicon area CREL (M.P. Dudukovic, P.A. Ramachandran and associates) developed the first models for the Siemens decomposer for silicon deposition by hydrogen reduction of chlorosilanes, for the Komatsu decomposer and aerosol reactor for silane pyrolysis, and for the fluidized bed for growth of silicon particles via silane pyrolysis. The latest effort contributed to the commercialization of a fluidized bed for silane pyrolysis by Ethyl Corporation. These fluidized beds still operate at Pasadena, Texas and are owned by MEMC. This was followed up by extensive modeling of the Czochralski crystal puller which resulted in suggestions for improved model based control of the process. Our work was rewarded by 2 NASA certificates of recognition. Finally, with the insight of H. Erk a novel design of an acid etcher for large silicon wafers was developed and implemented. All of the above know-how is available to sponsors.

• The effect of sonification on the fluid boundary layers at the flat solid surface (wafer) has been quantified and the magnitude of mass transfer intensification to and from the surface has been determined (H. Erk, M.P. Dudukovic).

III.PROCESS MONITORING AND CONTROL - (G. McMillan)

Our advances in understanding of multiphase systems and the implementation of reaction engineering methodology in preparation of new materials can be enhanced by coupling them with various techniques for process monitoring which are also needed for control. We are making sure that CREL students get exposed to advances in artificial intelligence, expert systems and computer technology; and we provide them with the opportunities to utilize and modify these by applying them to reactor design and materials preparation.

Currently, Dr. G. McMillan, retired Solutia Senior Fellow, is interested and can be available for working with MRE sponsors for the development of HYSYS plant dynamic model of the reactor and control system based on existing process and control system information. A brief outline of such proposed effort is enclosed in the report.

2. CREL ACHIEVEMENTS

Graduation

We are proud that four graduate students successfully completed their degrees in CREL during the 2007/2008 academic year.

W. Chentiang, completed his doctoral degree on bubble dynamics and heat transfer in slurry bubble columns. He is currently working at ConocoPhillips.

D. Guha, completed his doctoral degree on stirred tank reactors. He is currently working at ConocoPhillips.

A. Shaikh, completed his doctoral degree on slurry bubble column hydrodynamics. He is currently working at Eastman Chemicals.

V. Varma, completed his doctoral degree on anaerobic bioreactor and development of dual source gamma ray computed tomography (CSCT). He is currently working at Shell.

CREL Interactions:

CREL continues to maintain close contact with our industrial sponsors, National laboratories and academia all over the world.

• As part of the interaction between CREL and industrial sponsors that we encourage, some of our students and research associates held summer jobs on companies’ premises.

In the past years the following CREL students and associates held industrial summer jobs:

L. Han worked during the summer 2005 and 2006 at MEMC electronics, St. Louis

A. Henriques, worked during the summer 2005 and 2006 at USDA-Eastern Research Facility in Pittsburgh.

D. Guha worked during 2004 at Air Products and Chemicals.

J. Guo worked during 2004 at Corning.

Y. Jiang worked during the summer of 1999 at DuPont Engineering.

K. Balakrishnan worked during the Fall of 1999 at Monsanto.

Yu Pan worked closely with the scientists at Exxon Research and Engineering on

computational fluid dynamics and during 1999/2000 he frequently visited their premises.

P. Gupta and P. Chen participated during 1999/2000 in the radioactive tracer

experiments on the AFDU at LaPorte, Texas.

P. Gupta participated during the week of April 11, 1998 in the radioactive tracer

experiments on the AFDU at La Porte, Texas as part of a joint effort among DOE, Air

Products, Shell and Washington University.

Sairam Potaraju worked during the summer (May-August 1998) at Solutia, Houston.

S. Kumar, J. Chen, and P. Gupta spent a week in Summer 1996 at Exxon, Florham

Park, NJ.

S. Degaleesan was at Exxon, New Jersey for the Summer of 1994.

P. Gupta joined MEMC Electronic Materials, St. Peters, Missouri, for the

Summer of 1995.

S. Karur joined Upjohn, Michigan for the Summer of 1995.

M. Khadilkar joined Union Carbide, Charleston, for the Summer of 1995.

B. Zou joined Monsanto Enviro-Chem for the Summer and Fall of 1995.

• CREL has also developed strong links with nationally and internationally recognized groups in multiphase flow and reactors and intends to further strengthen such links with

- Dr. H. Van Den Akker, Kramers Laboratorium at Delft University, Holland

- Dr. R. Mudde, Kramers Laboratorium at Delft University, Holland

- Dr. H. Svendsen, Trondheim Institute of Technology of the University of Norway, Trondheim, Norway

- Dr. G. Eigenberger, University of Dortmund, Germany

- Dr. A. Lubbert, University of Hannover, Germany

- Dr. R. Lange, Dresden University, Germany

- Dr. B. Subramaniam, University of Kansas as a part of NSF-CEBC Center activities

- Dr. H. Kuipers, Twente University-Holland

- Dr. F. Larachi, Laval University, Canada

- Dr. J. Chaouki, Ecole Polytechnic, Canada

- Dr. J.C. Charpentier, CPE-Lyon, France

- Dr. K. Arcuri, Syntroleum

- Dr. C. Coulaloglou, ExxonMobbil

- Dr. J. Logsdon, Ineos Nitrile

- Dr. D. Depaoli, OakRidge National Laboratory

- Mr. D. Marshall and C. Barnes, Idaho National Laboratory

- Dr. S. Ram, Ansys Inc. (CFX code)

- Dr. Kashiwa, Los Alamos National Laboratory

- Dr. L.-S. Fan, Ohio State University

- Dr. S. Subbiah, Dr. Jay Sanyal and Dr. A. Haidari, Fluent

- Dr. Tim O’Hern and Dr. John Torczynski, , Sandia National Laboratories

- Dr. A. Laurent, Nancy, France

- Dr. J. Grace, University of British Columbia, Canada

- Dr. V. Ranade, National Chemical Laboratory, Pune, India

- Dr. N. Papayannakos, National Technical University of Athens, Greece

- Dr. Fernandez Sevilla, University of Almeria, Spain

- Dr. E. Molina Grima, University of Almeria, Spain

- Dr. S. Antal and Dr. R. Lahey, Rensselaer Polytechnic Institute

- Dr. R.V. Chaudhari, University of Kansas

- Dr. N. Nicola, University of Pretoria, South Africa

- Dr. V. Pareek, University of Curtin, Australia

- Dr. M. Cassanoli University of Bo Aires, Argentina

- Dr. S. Nedeltchev, National Academy of Science, Bulgaria

- Dr. M. Rafique, IBCAST, Pakistan Centers for Excellence in Science and Technology

- Dr. Roy, IIT, New Delhi, India

- Dr. S. Loyalka and Dr. T. Ghosh, University of Missouri, Columbia

- Dr. R. Gardner, North Carolina State University

Strengthening of these relationships through work on joint projects and exchange of personnel is being sought.

3. CREL PRODUCTIVITY AND FUNDING

We continue to report on various productivity measures of CREL such as degrees granted per year, number of graduate students and postdoctoral associates involved in research, and journal publications per year.

Table 1: CREL PRODUCTIVITY

Recent Doctoral and Master Degrees Granted for Work in CREL (1995 - present):

R. Varma, Characterization of Anaerobic Bioreactors for Bioenergy Generation Using a Novel Tomography Technique, 2008

D. Guha, Hydrodynamics and Mixing in Single Phase and Liquid-Solid Stirred Tank Reactors, 2007

C. Wu, Heat Transfer and Bubble Dynamics in a Slurry Bubble Column for Fischer-Tropsch Alternative Fuels, 2007

L. Han, Hydrodynamics and Mass Transfer in a Slurry Bubble Column Reactor, DSc, May 2007.

A. Shaikh, Bubble and Slurry Bubble Column Reactors for Syngas to Liquid Fuel Conversion: Mixing, Flow Regime Transition, and Scale-Up, DSc, May 2007.

M. Vesvikar, Understanding the hydrodynamics and performance of anaerobic digesters, DSc, August 2006.

Shaibal Roy, Phase distribution and performance studies of gas-liquid monolith reactor, DSc, Washington University, May 2006.

Fan Mei, Mass and energy balance for a corn-to-ethanol plant, MS, May 2006

RC Ramaswamy, Steady state and dynamic reactor models for coupling exothermic and endothermic reactions, DSc, May 2006.

Prakash Kumar, Aerosol routes for synthesis of nanostructured magnetic oxides: characterization and transport behavior, DSc, Washington University, August 2005.

S. Bhusarapu, Solids flow mapping in gas-solid riser, Dsc, August 2005.

Jing Guo, Catalytic wet oxidation over pillared clay catalyst in packed-bed reactors: Experiments and modeling, DSc, Spring 2005.

R. Hoffman, Effect of modeling on the performance of anaerobic digesters, MS, August 2005.

Huping Luo, Analyzing and modeling of airlift photobioreactors for microalgal and cyanobacteria cultures, DSc, August 2005.

Peng Chen, Fluid dynamic modeling of bubble column flows. DSc, Washington University, May 2004.

Booncheng Ong, Experimental investigation of bubble column hydrodynamics: Effect of elevated pressure and superficial gas velocity, DSc, Washington University, St. Louis, MO, May 2003.

Eusebio Palmisano, Wetting efficiency of complex shape catalyst in trickle bed reactors, MS, Washington University, 2003.

Novica Rados, Slurry bubble column hydrodynamics: Experimentation and modeling, DSc, Washington University, St. Louis, MO, May 2003.

Puneet Gupta, Churn-turbulent bubble columns: Experiments and modeling, DSc, Washington University, St. Louis, MO, May 2002.

Javier Alvare, Gas holdup and liquid phase mixing in trayed bubble column reactors, MS, Washington University, St. Louis, MO, August 2002.

Karthik Balakrishnan, Singularity methods in trickle bed reactors, DSc, Washington University, St. Louis, MO, May 2001.

Garima Bhatia, A reaction engineering analysis of charcoal formation in batch kilns, DSc, Washington University, St. Louis, MO, August 2001.

Yi Jiang, Flow distribution and its impact on performance of packed-bed reactors, DSc, Washington University, St. Louis, MO, December 2000.

Aravind Rammohan, Characterization of Flow Patterns in Stirred Tank Reactors, DSc, Washington University, St. Louis, MO, April 2000.

Shantanu Roy, Quantification of Two-Phase Flow in Liquid Solid Risers, DSc, Washington University, St. Louis, MO, December 2000.

Marco Roveda, Brominated Disinfection By-Product Formation During Ozonation of Bromide-Containing Waters, MS, Washington University, St. Louis, MO, May 1999.

Zhen Xu, Toluene to benzyl chloride, DSc, Washington University, St. Louis, MO, December 1998.

Mohan R. Khadilkar, Performance studies of trickle bed reactors, DSc, Washington University, St. Louis, MO, December 1998.

Stuart Wesley Highfill, Liquid-solid mass transfer coefficient in high pressure trickle-bed reactor, MS, Washington University, St. Louis, MO, December 1998.

Sujatha Degaleesan, Fluid dynamic measurements and modeling of liquid mixing in bubble columns, DSc, Washington University, St. Louis, MO, August 1997.

Bente Sannaes, Slurry Bubble Columns, DSc, Trondheim Institute of Technology of the University of Norway Trondheim, Norway, June 1997.

Robin L. Shepard, Carbon fibers for affordable polymeric composites, DSc, Washington University, St. Louis, MO, May 1996.

Milind S. Kulkarni, Dynamics of asymmetric fixed-bed reactors: Coupling of exothermic and endothermic reactions, DSc, Washington University, St. Louis, MO, December 1996.

Qingqi (Harry) Wang, Modeling of gas and liquid phase mixing with reaction in bubble column reactors, DSc, Washington University, St. Louis, MO, August 1996.

Kan-yin Ng, Gas Purification by Rotofilter, M.S., Washington University, St. Louis, MO, February 1996.

Sriganesh Karur, Boundary Element and Dual Reciprocity Methods in Reaction Engineering, DSc, Washington University, St. Louis, MO, May 1996.

Kanchana Kumar, Evaluation of Oxygen Releasing Materials for In Situ Bioremedial Processes, MS, Washington University, St. Louis, MO, December 1996.

Matthew Mark Thomas, Quality control of batch chemical processes with application of autoclave curing of composite laminate materials, DSc, Washington University, St. Louis, MO, December 1995.

NUMBER OF CREL GRADUATE STUDENTS (RESEARCH ASSOCIATES):

|YEAR |00/01 |

|Heat Transfer Coefficients in Slurry Bubble Columns |Chengtian Wu |

|Hydrodynamics of bubble columns with internals in an 8” column using air-water system |Ahmed Youseff |

|Measurement of Local Flow Structure in 2 D Bubble Column |Fadha Ahmed |

|Modeling of Vaporization and Cracking of Liquid Oil Injected in a Gas-Solid Riser |Subramanya Nayak |

|Transport in Nanoporous Zeolites Used in Alkylation Processes |Subramanya Nayak |

|Multiscale Research Approach for Measurement of Adsorption/ Desorption and Transport |Subramanya Nayak |

|Properties | |

|Hysteresis in a High Pressure Trickle Bed Reactor |Zeljko Kuzeljevic |

|Trickle Bed Hydrogenation Reactors: Modeling of Non-Isothermal Effects |Dan Combest |

|Modeling of Laboratory and Commercial Scale Hydro-processing Reactors using CFD |Prashant Gunjal |

|Multi-domain Global Model for Czochralski (Cz) Crystal Growth Process for Pure Silicon |Prashant Gunjal |

|Volumetric Expansion, Phase Transition and Bubble Dynamics in Multiphase Systems Using a |Sean Mueller |

|Fiber-Optic Probe | |

|Large-Diameter Phantom Study by Gamma Transmission Tomography |Pablo Vasquez-Salvador |

|Application of Alternating - Minimization (AM) in Dual Source Gamma Ray Computed Tomography |Rajneesh Varma |

|for Imaging Three Phase Systems | |

|Synergistic Study of Cell Wall Degrading and Proteolytic Enzymes for Enzymatic Water Removal|Bia Henriques |

|from Distillers Grains | |

|The Oxidation of Cyclohexane-Stirred Tank Study |Radmila Jevtic |

|The Oxidation of Cyclohexane-Study in A Capillary |Radmila Jevtic |

| | |

|GUESTS | |

|Evaporation induced self assembly and rheology change during sol-gel coating |Chang Lee |

|A Kinetic Study of Single Particle Experiments using Temporal Analysis of Products (TAP) |Xiaolin Zheng |

|Reactor | |

|Advancing the Fundamental Understanding and Scale-up of Spouted Bed TRISO Coaters |Haoyang Liu |

| |and Derek Starkey |

4. CREL FUTURE DIRECTIONS

We will continue to work on developing a scientific base for an improved multiphase reactor methodology and understanding for scale-up/scale-down and design and on providing service to our sponsors.

Our goal for the next few years is to maintain a balanced experimental and computational approach to studies of multiphase reaction engineering.

On the experimental side we want to:

i) Extend our effort on energy, environment and benign and energy efficient processes development by evaluating new catalysis, kinetics, new medium and efficient reactor type. This includes the development of mini and micro reactors.

ii) Extend our unique RPT/CT/ This includes extending RPT-CT data based to new reactor types such as gas-solid riser, fluidized beds, stirred tanks, ebullated beds, moving beds, slurry systems with and without internals, and multiphase bioreactors.

iii) Augment the experimental base with techniques for bubble dynamics, heat transfer, mass transfer and for other measurements.

iii) Develop multiparticle tracking (MRPT) and dual source computed tomography (DSCT) techniques.

On the computational side we will continue the development of kinetic and reactor scale mechanistic models and the evaluation of various closures to identify the best closure schemes utilization of the two fluid model based codes for multiphase systems. We are initiating the effort to package our developed model into user-friendly programs and software that can be readily used by students, engineers and plant operators.

Our research on improved unsteady state processing, environmentally friendly processes, novel reactors, microreactors, monolith/structured packing beds and multiphase bioreactors will continue.

We are continuing our research activities as a part of the NSF-CEBC for the development of environmentally benign processes by replacing the currently used chemical solvents in industry with supercritical CO2 and/or expanded bed - a mixture of chemical solvent and supercritical CO2. Also we are initiating research activities on bioenergy with the collaboration of ethanol pilot plant -Southern Illinois University (SIU) and USDA which complements our current activities of methane production from animal land farm waste supported by DOE.

In addition, we actively seek to participate with industrial partners in new process development efforts.

Finally, we are providing the opportunity to the interested companies of establishing a new venture of providing HYSYS based advanced control platform founded on model based control for control and optimization of various industrial processes and reactor types.

[pic]

................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download