Commercial scale slurry bubble column reactor optimization

An in-depth numerical study has been carried out to investigate a high-pressure commercial scale (2–8 meter diameter) slurry bubble column reactor (SBCR). Typical superficial gas velocities are in the range of 0.5–3 m/s, and overall vapor hold-ups are in the range of 0.45–0.85. The study revealed that steady compartmental reaction models do not match plant data when reaction time constants are very fast. Also, off-the-shelf commercial CFD codes do not produce useful information about a reactive column of this scale and aeration without tuning to reconcile with vapor hold-up and reactant operating data “anchors” from in-plant units. Important measures include both transient and time-averaged profiles, integrals, and extrema of vapor hold-up and reactants. The present study proposes reactor designs that improve productivity and product quality.