Chemical & Process Engineering

Scale-up methodology for batch phase separation of stirred liquid-liquid systems

Motivation

In many industrial applications, processes are operated discontinuously. Examples are two-phase reactions in stirred tanks or liquid-liquid extractions, where it is often necessary to separate the two phases before further processing. Insufficient methods exist for the design and optimization of this separation step, especially for the scale-up from laboratory to technical scale. In particular, the prediction of the drop size distribution (DSD) in the technical apparatus and, derived from this, the interfacial area in the dispersed state as well as the phase separation behavior has not been possible with certainty to date on the basis of laboratory tests (see Figure 1). This means that optimum apparatus dimensioning and operational management cannot be guaranteed.

Approach

In the project, a scale-up methodology is developed specifically for stirred liquid/liquid systems. For this purpose, experimental investigations will be carried out on three different size scales (1 L, 30 L and 500 L). Industrially relevant stock systems (toluene/water, butyl acetate/water and kerosene oil/water) are used, important operating parameters such as dispersed phase fraction, power input, mixing time and stirrer geometry are varied and dispersion and phase separation behavior are analyzed in detail. The model developed based on the results at the 1L scale will be validated and adapted at the other two scales. Thus, a standardized, cross-scale design methodology will ultimately be developed. The basic scheme of the project is shown in Figure 2.

Publications

2019

Villwock, J.
Systematische Analyse des Koaleszenzverhaltens von zweiphasigen Flüssigsystemen bei Ionenzugabe
TU Berlin
2019

2017

Kamp, J.; Villwock, J.; Kraume, M.
Drop coalescence in technical liquid/liquid applications - A review on experimental techniques and modelling approaches
Reviews in Chemical Engineering, 33 (1) :1-47
2017
ISSN: 2191-02350

2016

Gebauer, F.; Villwock, J.; Kraume, M.; Bart, H.-J.
Detailed analysis of single drop coalescence - Influence of ions on film drainage and coalescence time
Chemical Engineering Research and Design, 115 (B) :282-291
2016
ISSN: 0263-8762
Gebauer, F.; Villwock, J.; Kraume, M.; Bart, H.-J.
Prädiktiver Ansatz zur Beschreibung von Koaleszenzereignissen
Chemie Ingenieur Technik, 88 (9) :1287
2016
ISSN: 1522-2640
Villwock, J.; Gebauer, F.; Bart, H.-J.; Kraume, M.
Vom Einzeltropfen zum Tropfenschwarm - Systematische Analyse der Koaleszenz in Flüssig/Flüssig-Systemen bei Ionenzugabe
Chemie Ingenieur Technik, 88 (9) :1299-1300
2016
ISSN: 1522-2640

2015

Villwock, J.; Kamp, J.; Gebauer, F.; Bart, H.-J.; Kraume, M.
Coalescence in liquid/liquid dispersions - Influence of ions and fluid dynamics
In European Federation of Chemical Engineering, Editor, Abstract Book of the 10th European Congress of Chemical Engineering, Page 554
In European Federation of Chemical Engineering, Editor
2015
ISBN
978-2-910239-82-4
Gebauer, F.; Villwock, J.; Kraume, M.; Bart, H.-J.
Einfluss von Stoffsystem und Fluiddynamik auf lokale Koaleszenzphänomene in Flüssig/Flüssig-Systemen
Chemie Ingenieur Technik, 87 (8) :1055
2015
ISSN: 1522-2640
Villwock, J.; Kamp, J.; Gebauer, F.; Bart, H.-J.; Kraume, M.
Influence of Ions and Fluid Dynamics on Coalescence in Liquid/Liquid Dispersions
Proceedings of the 2015 AIChE Annual Meeting
2015
ISBN
978-0-8169-1094-6
Villwock, J.; Kamp, J.; Gebauer, F.; Bart, H.-J.; Kraume, M.
Koaleszenz in Flüssig/Flüssig-Systemen - Einfluss von Ionen und Fluiddynamik
Chemie Ingenieur Technik, 87 (8) :1055-1056
2015
ISSN: 1522-2640

2014

Villwock, J.; Gebauer, F.; Bart, H.-J.; Kraume, M.
Systematische Untersuchung des Einflusses von Ionen auf die Koaleszenz von Einzeltropfen
Chemie Ingenieur Technik, 86 (9) :1460-1461
2014
ISSN: 1522-2640
Villwock, J.; Gebauer, F.; Kamp, J.; Bart, H.-J.; Kraume, M.
Systematic analysis of single droplet coalescence
Chemical Engineering & Technology, 37 (7) :1103-1111
2014
Villwock, J.; Kamp, J.; Kraume, M.
Systematic Analysis of Coalescence in Liquid/Liquid Dispersions
In Kraume, M. and Wehinger, G., Editor, Conference Proceedings of the 20th International Conference of Process Engineering and Chemical Plant Design, Page 119-126
In Kraume, M. and Wehinger, G., Editor
2014
ISBN
978-3-00-047364-7
Villwock, J.; Kamp, J.; Gebauer, F.; Bart, H.-J.; Kraume, M.
From Single Drop Experiments to Stirred Tanks - Systematic Analysis of Coalescence in Liquid/Liquid Dispersions
Proceedings AIChE Annual Meeting 2014, Atlanta 16.-21.11.2014
2014
ISBN
978-0-8169-1086-1

2013

Gebauer, F.; Hlawitschka, M.-W.; Villwock, J.; Kamp, J.; Bart, H.-J.; Kraume, M.
CFD-Simulation von binärer Tropfenkollision unter Berücksichtigung von Koaleszenz- und Repulsionsereignissen
Chemie Ingenieur Technik, 85 (9) :1382
2013
ISSN: 1522-2640
Villwock, J.; Kamp, J.; Kraume, M.; Gebauer, F.; Bart, H.-J.
Einzeltropfenuntersuchungen zur Koaleszenzeffizienz unter dem Einfluss von Ionen
Chemie Ingenieur Technik, 85 (9) :1398
2013
ISSN: 1522-2640
Gebauer, F.; Villwock, J.; Kamp, J.; Bart, H.-J.; Kraume, M.
Koaleszenzphänomene im Einzeltropfenexperiment: Einfluss von Ionenzugabe auf Filmriss und Koaleszenzzeit
Chemie Ingenieur Technik, 85 (9) :1400
2013
ISSN: 1522-2640

2009

Villwock, J.; Iversen, V.; Drews, A.; Lesjean, B.; Kraume, M.
Combination of flux enhancers for MBR
Final MBR-Network Workshop, Berlin, 31.0.-01.04.09, Page 175-176
2009
ISBN
978-3-9811684-5-7
Iversen, V.; Villwock, J.; Torre Garcia, T.; Drews, A.; Kraume, M.
Impact of MBR flux enhancer on floc size distribution, dewaterability and shear stability
Desalination and Water Treatment, 6 :33-40
2009
Stumpf, D.; Villwock, J.; Heinzmann, B.; Kraume, M.
Induced MAP-precipitation in digested sludge for reuse as magnesium ammonium phosphate for fertilizer
Proceedings BALTIC 21 Conference "Phosphorus Recycling and Good Agricultural Management Practice", Berlin, 28.09.-30.09.2009
2009

2008

Iversen, V.; Villwock, J.; Koseoglu, H.; Yigit, N.O.; Kitis, M.; Drews, A.; Kraume, M.
Filtrierbarkeit und Scherstabilität von geflocktem Belebtschlamm
Chemie Ingenieur Technik, 80 :1313
2008
Iversen, V.; Villwock, J.; Torre, T. De; Drews, A.; Kraume, M.
Impact of flux enhancer for MBR on floc size distribution, dewaterability and shear stability
Page 23 (Abstract)
2008

2005

Vocks, M.; Gnirss, R.; Lesjean, B.; Villwock, J.; Kraume, M.
Membrane bioreactors coupled with low-pressure sewer for decentralized wastewater treatment
1st Zero-M Conference on Sustainable Water Management, Instanbul/Turkey, 15.-16.03.2005, Page 33-37
2005