Search Results (67)

The transition to low-carbon energy systems requires efficient hydrogen production methods that minimise CO₂ emissions. This study presents a techno-economic assessment of hydrogen production via methane pyrolysis, utilising a novel liquid metal bubble column reactor (LMBCR) designed for CO₂-free hydrogen and solid carbon outputs. Operating at 20 bar and 1100 °C, the reactor employs a molten nickel-bismuth alloy as both catalyst and heat transfer medium, alongside a sodium bromide layer to enhance carbon purity and facilitate separation. Four operational scenarios were modelled, comparing various heating and recycling configurations to optimise hydrogen yield and process economics. Results indicate that the levelised cost of hydrogen (LCOH) is highly sensitive to methane and electricity prices, CO₂ taxation, and the value of carbon by-products. Two reactor configurations demonstrate competitive LCOHs of 1.29 $/kgH₂ and 1.53 $/kgH₂, highlighting methane pyrolysis as a viable low-carbon alternative to steam methane reforming (SMR) with carbon capture and storage (CCS). This analysis underscores the potential of methane pyrolysis for scalable, economically viable hydrogen production under specificmarket conditions. Full article

This study investigates the viability of a native Scenedesmus sp. strain for use in a 50 L bubble column photobioreactor designed to reduce greenhouse gas emissions under simulated spring, extreme summer, and winter conditions. The experiments were conducted by placing the reactor in a controlled climatic chamber, which allowed us to regulate the temperature, light intensity, and day–night cycles throughout the entire experiment. The results showed that under simulated spring conditions (a maximum temperature of 22 °C), the algal culture grew continuously for 61 days. Under extreme summer conditions (a maximum temperature of 39 °C), an initial drop in cell density was followed by recovery and continued growth over 75 days, although biomass production was 35% lower. Under winter conditions (a maximum temperature of 10 °C), the culture failed, indicating the need to prevent temperatures below 10 °C. In terms of biomass production, the culture densities achieved were 1.04 g L⁻¹ and 0.68 g L⁻¹ in the spring and summer trials, respectively. The Scenedesmus sp. strain demonstrated high carbon capture efficiency, tolerance to extreme heat, and sustained growth without the need for fresh medium or pH adjustments for over 60 days during spring and extreme summer conditions, confirming its potential for outdoor applications. Full article

To enhance contact time between microalgae and nutrients in reactors, thereby improving the growth rate of microalgae and increasing pollutant removal efficiency, two funnel-shaped spoilers were added inside a traditional column photobioreactor. Compared to conventional column photobioreactors, the addition of these spoilers resulted in increased updraft, which improved horizontal flow. This change led to a greater shear force near the spoilers and a reduction in bubble diameter. As a result, the mass transfer coefficient and gas content increased by 12.17% and 7.71%, respectively, while the mixing time decreased by 30.57%. These improvements resulted in an 18.18% increase in microalgal biomass, a 13.95% increase in the CO₂ fixation rate, and increases of 4.48%, 7.5%, and 4.7% in the removal of COD, TP, and NH₄⁺-N, respectively, in the column photobioreactor with funnel-shaped spoilers. This was achieved when CO₂ was introduced at a concentration of 10%, compared to a conventional column photobioreactor. This innovative design enhances the growth efficiency of microalgae, offering a new solution for reducing carbon emissions, promoting recycling of water resources, and advancing sustainable development. Full article

Kojic acid (KA) is an economically important molecule, due to its functions as an anti-inflammatory, antifungal, and facial skin-lightening agent. Considering the wide application of this metabolite, it is essential to study processes that increase or improve its production. The objective of this study was to evaluate the effect of agitation on fungal KA production. To evaluate the effect of agitation on fungal KA production, liquid medium fermentation was carried out using batch bioreactors with a capacity of one liter. The Aspergillus oryzae strain was used, with glucose as the sole carbon source. Three experimental factors were evaluated: illumination (light or darkness), agitation type (no agitation, bubbling, and tangential), and time (0, 24, 48, 72, 96, 120, 144, 168 h). The evaluated variables included pH, product-to-biomass yield, protein content, reducing sugar consumption, and KA concentration. The bubbling level with light for 144 h showed the highest efficiency by producing 7.86 ± 2.21 g KA/L. The production of KA in liquid medium with the fungus A. oryzae requires bubbling conditions with light to achieve the best yields and production. The findings in this study provide insights into the influence of agitation conditions on KA biosynthesis and its potential for scaling up industrial fermentation. However, future work could investigate the metabolic and genetic mechanisms of this enhanced production to generate more efficient biotechnological applications for KA production. Full article

This study aims to contribute to the optimization of bio-methanation in bubble columns, making it a more viable alternative to stirred tank reactors. The primary challenge to be addressed is the enhancement of mass transfer, which strongly depends on parameters such as bubble size and gas hold-up. Various disperser designs were examined in a 0.14 mm diameter column, comparing their performance in terms of bubble diameter distribution and gas hold-up. The results indicate that an optimized plate disperser featuring a porous structure outperformed other designs by maintaining high gas retention without significant coalescence. Additionally, newly developed plug-in dispersers allowed for counter-current flow operation, enhancing process flexibility. Commercially available porous pin dispersers produced smaller bubbles compared to the other designs, yielding high gas hold-ups at lower gas velocities. Correlations between disperser type and column design parameters were established, laying the foundation for apparatus optimization. The findings contribute to the development of digital twin models, facilitating the refinement of bio-methanation processes within bubble columns for increased efficiency. Full article

In this study, in a three-phase reactor with a rectangular cross-section, the effects of liquid circulation rates and solid particle concentration on gas holdup and bubble size distribution (BSD) were investigated. Air, water, and glass beads were used as the gas, liquid, and solid phases, respectively. Different liquid circulation velocities and different solid loads were applied. The results demonstrate that increasing solid content from 0% to 6% can decrease gas holdup by 50% (due to increased slurry phase viscosity and promotion of bubble coalescence). Also, increasing the liquid circulation rate showed a weak effect on gas holdup, although a slight incremental effect was observed due to the promotion of bubble breakup and the extension of bubble residence time. The gas holdup in counter-current slurry bubble columns (CCSBCs) was predicted using a novel correlation that took into account the combined effects of solid concentration and liquid circulation rate. These findings are crucial for the design and optimization of the three-phase reactors used in industries such as mining and wastewater treatment. Full article

This study endeavors to develop an economical and user-friendly biological sulfide oxidation system and explore its mechanism for generating biological elemental sulfur under micro-aerobic conditions using psychrophilic anaerobically digested media (liquid/solid inoculums obtained from agricultural livestock wastes) for sulfide-free biogas production. With an initial hydrogen sulfide concentration of 5000 ppm, a biogas flow rate ranging from 0.9 to 1.8 L/h-L_inoculum-mix, and an air injection rate of 0.6–1% (oxygen concentration in biogas), a remarkable biodesulfurization efficiency of 99–100% was attained using solid inoculum as the biodesulfurization medium. This efficiency was achieved without compromising the methane quality in the treated biogas. Compared to liquid inoculum, solid inoculum requires less than half the volume and no mixing equipment, such as bubble column reactors. The biodesulfurization reactor requires only 1 m³, which is approximately 1.5% of the volume of a wet anaerobic digester and 3% of a dry anaerobic digester, while processing cow manure (Total Solids: 20%) at 1.03 m³ of manure per day. Moreover, it can be operated at (19–20 °C), leading to substantial reductions in cost and footprint. Full article

Due to the complex relationship between various parameters affecting gas holdup in bubble column reactors, a unique correlation for gas holdup does not exist. The available correlations proposed in the literature for gas holdup prediction in aqueous alcohol solutions in bubble columns fail to predict gas holdup over a wide range of conditions. Therefore, based on around 1000 data points from the previous studies, an empirical correlation and a trained model were derived using the dimensionless numbers Reynolds, Froude, Eötvös to Morton ratio, and alcohol carbon number. The predictions were compared to experiments with different water–alcohol mediums at various concentrations to validate the correlation and trained model, and a good agreement was observed. However, the ML model was predicting more accurately, and it was indicated that the Reynolds number had the most significant impact on gas holdup, followed by the Eötvös to Morton ratio. Full article

Furfural is one of the main pollutant materials in petroleum refinery wastewater. This work used an ozonized bubble column reactor to remove furfural from wastewater. The reactor applied two shapes of packing materials and two dosages of CuO nanocatalyst (0.05 and 0.1 ppm) to enhance the degradation process. The results indicated that adding 0.1 ppm of nanocatalyst provided an efficient rate of furfural degradation compared to that of 0.05 ppm. Also, the packing materials enhanced the furfural degradation significantly. As a result, the contact area between the gas and liquid phases increased, and a high furfural removal efficiency was achieved. It was found that the CuO nanocatalyst generated more (OH•) radicals. At a treatment time of 120 min and an ozone flow of 40 L/h, the furfural degradation recorded values of 80.66 and 78.6% at 10 and 20 ppm of initial concentration, respectively. At 60 ppm, the degradation efficiency did not exceed 74.16%. Furthermore, the kinetic study indicated that the first-order mechanism is more favorable than the second-order mechanism, representing the furfural degradation with a correlation factor of 0.9837. Finally, the furfural reaction can be achieved successfully in a shorter time and at low cost. Full article

Due to its unique physicochemical properties, Pullulan is an exopolysaccharide with many applications in the food, biomedical, and pharmaceutical industries. Aiming to reduce its production cost, an interesting alternative is to consider other possibilities of raw materials, including the production of this biopolymer in a lignocellulosic biorefinery concept. Xylose is the main sugar of hemicellulosic hydrolysates obtained from different biomasses, and it is a sugar still not extensively exploited regarding its potential for pullulan production. This study aimed to evaluate the production of pullulan from sugarcane bagasse hemicellulosic hydrolysate by cultivating Aureobasidium pullulans ATCC 42023 in a bubble column reactor. The hemicellulosic hydrolysate was obtained through dilute acid treatment carried out in a stirred tank reactor before being detoxified to remove microbial growth inhibitors. The maximum concentration of 28.62 ± 1.43 g/L of pullulan was obtained after 120 h of fermentation in a bubble column reactor in batch mode. Analysis of spectroscopic properties through FTIR of the obtained pullulan revealed α-(1→6)-linked maltosyl units, similar to those of commercial samples of the biopolymer. XRD analysis showed that the prepared pullulan is amorphous, and a homogeneous morphology with a smooth surface of the pullulan was observed in SEM analysis. This study showed the potential of the production of pullulan from sugarcane bagasse hemicellulosic hydrolysate in a bubble column bioreactor, an alternative strategy for the industrial production of this biopolymer. Full article

The Elastic Catalytic Foam-bed Reactor (EcFR) technology was used to enhance a model catalytic hydrogenation reaction by improving gas–liquid mass transfer. This advanced technology is based on a column packed with a commercial elastomeric polyurethane open-cell foam, which also acts as a catalyst support. A simple and efficient crankshaft-inspired system applied in situ compression/relaxation movements to the foam bed. For the first time, the catalytic support parameters (i.e., porosity, tortuosity, characteristic length, etc.) underwent cyclic and controlled changes over time. These dynamic cycles have made it possible to intensify the transfer of gas to liquid at a constant energy level. The application chosen was the selective hydrogenation of phenylacetylene to styrene in an alcoholic solution using a palladium-based catalyst under hydrogen bubble conditions. The conversion observed with this EcFR at 1 Hz as cycle frequency was compared with that observed with a conventional Fixed Catalytic Foam-bed Reactor (FcFR). Full article

Bubble columns are widely used in numerous industrial processes because of their advantages in operation, design, and maintenance compared to other multiphase reactor types. In contrast to their simple design, the generated flow conditions inside a bubble column reactor are quite complex, especially in continuous mode with counter-current liquid flow. For the design and optimization of such reactors, precise numerical simulations and modelling are needed. These simulations and models have to be validated with experimental data. For this reason, experiments were carried out in a laboratory-scale bubble column using shadow imaging and particle image velocimetry (PIV) techniques with and without counter-current liquid flow. In the experiments, two types of gases—relatively poorly soluble air and well-soluble CO₂—were used and the bubbles were generated with three different capillary diameters. With changing gas and liquid flow rates, overall, 108 different flow conditions were investigated. In addition to the liquid flow fields captured by PIV, shadow imaging data were also statistically evaluated in the measurement volume and bubble parameters such as bubble diameter, velocity, aspect ratio, bubble motion direction, and inclination. The bubble slip velocity was calculated from the measured liquid and bubble velocities. The analysis of these parameters shows that the counter-current liquid flow has a noticeable influence on the bubble parameters, especially on the bubble velocity and motion direction. In the case of CO₂ bubbles, remarkable bubble shrinkage was observed with counter-current liquid flow due to the enhanced mass transfer. The results obtained for bubble aspect ratio are compared to known correlations from the literature. The comprehensive and extensive bubble data obtained in this study will now be used as a source for the development of correlations needed in the validation of numerical simulations and models. The data are available from the authors on request. Full article

For technical application with continuous operation of sorption-enhanced (SE) reactions, e.g., Fischer–Tropsch, a special reactor concept is required. SE processes are promising due to the negative effects of water on conversion and catalyst. The reactor concept of two interconnected slurry bubble columns combines the reaction with in situ water removal in the first, and sorbent regeneration in the second column with continuous exchange of slurry between the two. The liquid circulation rate (LCR) between the columns is studied in a cold flow model, measured by an ultrasonic sensor. The effects of different operating and geometric parameters, e.g., superficial gas velocity, liquid level and tube diameter on gas holdup and LCR are discussed and modelled via artificial intelligence methods, i.e., extremely randomized trees and neural networks. It was found that the LCR strongly depends on the gas holdup. The maximum of 4.28 L min⁻¹ was reached with the highest exit, widest tube and highest superficial gas velocity of 0.15 m s⁻¹. The influence of liquid level above the exit was marginal but water quality has to be considered. Both models offer predictions of the LCR with errors < 6%. With an extension of the models, particle circulation can be studied in the future. Full article

With the increasing use of renewable energy resources for the power grid, the need for long-term storage technologies, such as power-to-gas systems, is growing. Biomethanation provides the opportunity to store energy in the form of the natural gas-equivalent biomethane. This study investigates a novel plug flow reactor that employs a helical static mixer for the biological methanation of hydrogen and carbon dioxide. In tests, the reactor achieved an average methane production rate of 2.5 $\frac{L_{{CH}_4}}{L_R\ast \mathrm{d}}$ (methane production [L_CH4] per liter of reactor volume [L_R] per day [d]) with a maximum methane content of 94%. It demonstrated good flexibilization properties, as repeated 12 h downtimes did not negatively impact the process. The genera Methanothermobacter and Methanobacterium were predominant during the initial phase, along with volatile organic acid-producing, hydrogenotrophic, and proteolytic bacteria. The average ratio of volatile organic acid to total inorganic carbon increased to 0.52 ± 0.04, while the pH remained stable at an average of pH 8.1 ± 0.25 from day 32 to 98, spanning stable and flexible operation modes. This study contributes to the development of efficient flexible biological methanation systems for sustainable energy storage and management. Full article

Methane pyrolysis in molten catalyst bubble (MCB) column reactors is an emerging technology that enables the simultaneous production of hydrogen and solid carbon, together with a mechanism for separating the two coproducts. In this process, methane is dispersed as bubbles into a high temperature molten catalyst bath producing hydrogen and low-density carbon, which floats to the surface of the bath from providing a means for them to be separated. However, the removal of carbon particulates from a bubbling column reactor is technically challenging due to the corrosive nature of the molten catalysts, contamination of the product carbon with the molten catalysts, high temperatures and lack of understanding of the technology options. Four potential concepts for the removal of carbon particulate from a methane pyrolysis molten metal bubble column reactor are presented, based on the pneumatic removal of the particles or their overflow from the reactor. The concepts are evaluated using a cold prototype reactor model. To simulate the operation of a high-temperature reactor at low temperatures, the dominant dimensionless numbers are identified and matched between a reference high-temperature reactor and the developed cold prototype using water, air and hollow glass microsphere particles as the representatives of the molten catalyst, gaseous phases and solid carbon particulates, respectively. The concepts are tested in the cold prototype. High rates of particle removal are achieved, but with different tradeoffs. The applicability of each method together with their advantages and disadvantages are discussed. Full article