Dynamic tank-in-series modelling and simulation of gas-liquid interaction in trickle bed reactor designed for gas fermentation

Trickle bed reactors (TBR), historically utilized in petroleum processing and wastewater treatment, now extend their applicability in biological gas conversions, including syngas biomethanation for renewable methane production. Despite operational benefits, optimizing TBR design and scale-up demands a good understanding of the reactor’s hydraulic behavior and mass transfer phenomena. This study’s novelty is TBR’s hydraulic characterization in respect to liquid and gas flowrates and simulation of the gas-liquid interaction by a dynamic gas-liquid transfer model. Residence time distribution (RTD) experiments in 220 mL lab- and 5000 mL pilot-scale TBRs with co-current flow of gas and liquid were conducted to determine the liquid and gas working volume and the number of tanks for a dynamic tank-in-series (TIS) model. RTD experiments revealed 2 – 6 tanks for varying liquid flowrate (constant gas flowrate) and 5 – 8 tanks for varying gas flowrate (constant liquid flowrate). A dimensionless equation, fitted to RTD experimental data, predicted the liquid working volume of a TBR at various liquid flowrates and reactor configurations. TBR simulation by TIS model considering 8 well mixed gas and liquid phase tanks connected in series, resulted in an excellent model validation with an R² at 0.99. Finally, the model simulated the mass transfer kinetics of H₂, CO, and CO₂ in water under varying gas and liquid flowrates for lab- and pilot-scale TBRs. Simulation results showed increased dissolved gas concentration with higher gas flowrate (constant liquid flowrate) for both scales TBR. It was also noticeable that under constant gas flowrate, the dissolved gas concentration initially decreased (0.01 < Re_L < 17), then increased (17 < Re_L < 34), and again decreased (34 < Re_L < 105). This behavior was the same for both scales TBR and revealed an optimum Re_L value irrespective of TBR size.