Kinetic similarity as a scaling strategy for batch adsorption reactors to ensure efficient decolorization of sugar syrup on a larger scale

This study aimed at developing a scale-up method for the optimal design of stirred tank reactors and their corresponding batch processes for absorption applications. Three geometrically similar reactors (3, 30, and 300 L) were constructed to conduct ion exchange and surface adsorption experiments. Mathematical analysis revealed that in systems with combined "intraparticle-liquid film" mass transfer resistance, maintaining (m/V) = Idem and ND^0.667 = Idem ensures kinetic similarity, achieving C(t)_Bench = C(t)_Industrial. The discrepancy between suspension level and kinetic similarity was resolved through a cautious scale-up procedure. Equal power-to-volume ratios (P/V) across reactors yielded overlapping concentration histories, confirming P/V as a reliable scale-up criterion. Liquid film mass transfer coefficients were consistent under identical P/V conditions, validating the proposed scaling rule. Application to a sugar syrup decolorization unit demonstrated that a 14 m³ vessel with 10 g/L carbon dosage and 15 batches/shift minimized net present cost.