Trickle flow hydrodynamic multiplicity: Experimental observations and pore-scale capillary mechanism

Trickle bed reactors are encountered throughout the process industry. Considerable attention has been given to the study of the hydrodynamics of this type reactor. It has been identified that, in the trickle flow regime, the hydrodynamic parameters (e.g. pressure drop and liquid holdup) are not unique functions of the operating and system conditions, but depend on the flow history. This study reviews the experimental trends identified in literature on the basis of a limiting cases framework and then evaluates the three-dimensional pore-scale liquid distribution using computed tomography (CT) data. This leads to the identification of 20 phenomenological trends that characterize hydrodynamic multiplicity, including hydrodynamic flow hysteresis as well as the effects of pre-wetting. The CT study yields additional experimental insight into the role of capillary pressure and ultimately leads to the proposal of a capillary gate mechanism based on contact angle hysteresis as the root cause of multiplicity. The mechanism is incorporated into a simple pore-network model. It is shown that the qualitative performance of the model corresponds closely to the majority of phenomenological trends and is capable of explaining the observed experimental behaviour.