High-gravity and high-shear gas–liquid contactors for the chemical process industry

Intensification of chemical processes leads to significantly smaller equipment with a considerable reduction in holdup of liquids and gases, thus reducing the impact of chemical hazards. Also, different, more expensive, construction materials and specialty coatings can be used, thereby increasing safety and durability of equipment. Additionally, the waste production can be reduced as a result of the higher mixing efficiency and better control of chemical conversion processes, which reduces environmental impact and increases resource efficiency. The thin-film spinning disc (TFSD), the rotor–stator spinning disc (RSSD), and a combination of these, are highly attractive for highly reactive, exothermic reactions in multiphase systems. A barrier for industrial application is its success: demonstration requires hazardous chemicals in large quantities and flows and is not easily done in university laboratories. A piloting facility with sufficient resources is needed where this and other process intensification equipment can be safely tested.

► The thin-film spinning disc, the rotor–stator spinning disc, and the thin-film-rotor–stator spinning disc have high rates of mass transfer and high heat transfer.
► Suitable for hazardous, highly reactive, highly exothermic reactions in multiphase systems.
► Barrier to industrial application because these reactions involve hazardous chemicals in large quantities and flows.
► Step from university laboratories to industrial applications requires a piloting facility for safe testing.