Three-Dimensional CFD Simulations for Characterization of a Rectangular Bubble Column with a Unique Gas Distributor Operating at Extremely Low Superficial Gas Velocities

In the present work, three-dimensional (3D) simulations have been performed for the characterization of a rectangular column for a uniform gas distributor with µm-sized holes at a ratio of 5. The model is first validated with experimental data from the literature. Simulations are then performed for a gas distributor with identical pitch but two different hole sizes, namely 600 µm and 200 µm. Three superficial gas velocities, namely 0.002 m/s, 0.004 m/s, and 0.006 m/s, were used for each distributor type. The gas movement in the fluid is found to be a strong function of hole size. For a 600 µm hole size, the operating condition has minimal impact on gas plume movement and moves centrally in a fully aerated regime. However, for a hole size of 200 µm, for all superficial velocities, the gas plume movement is dynamic and partially aerated. The plume moves along the right wall initially and then follows vertically. These characteristics are different from the meandering plume in centrally located spargers. The liquid mixing in the bulk is a function of time. During the plume development flow, different shapes are observed. Based on the analogy with the shapes found in nature, these shapes have been termed as balloon, cap, jet or candle flame, bull horn, mushroom, tree shape, and disintegrated mushroom shapes. Quantitative insights have been obtained in the form of time-averaged radial profiles of both volume fractions and liquid axial velocities. A symmetric parabolic shape for a hole size of 600 µm and skewed asymmetric shapes for a 200 µm hole size for three different axial positions, namely 0.1, 0.25, and 0.4 m, are observed. Correlations for gas holdup and liquid velocity have been proposed for low superficial velocities, which are in good agreement with the CFD simulation data, with a deviation of 15-20%. The deviations are partly due to the use of the k-ε turbulent model. The correlations perform better than the correlations available in the reported literature for similar superficial gas velocities.