Liquid flow field and residence time distribution in a baffleless oscillatory flow coil reactor

Baffleless coils can operate as continuous oscillatory flow reactors to produce pharmaceutical products where process intensification is intended. A method to evaluate mixing performance and its impact on reaction conversion is residence time distribution (RTD) analysis. Liquid macromixing in a long baffleless coil reactor (L = 24 m, dt = 4.57 mm) at ranges of oscillation amplitude (11.75–58.75 mm), frequency (0–3.68 Hz), and net flow rate (30–120 g∙min−1) was investigated based on measured RTDs fitted to the skewed normal distribution model. The impact of operating conditions on the RTD was supported by analyzing the liquid flow field derived from CFD simulations. The RTD variance under different oscillation conditions suggests a near plug flow pattern, although deviations from ideality such as skewness and long tailing were always observed. The model parameters, along with the RTD variance, were correlated to the operating conditions lumped in an oscillatory Dean number that used the flow amplitude as characteristic length (Deox). Values of Deox varied between 150 and 11000, and the RTD variance at the different net flow rates was minimized for 300 < Deox < 600, as also evidenced from the minimum cross-sectional variance of the simulated time-averaged axial velocity profile. Normalizing the data allowed comparison to similar coil studies with different geometrical dimensions and operating conditions, leading to generalized correlations for the RTD model parameters. Finally, chemical conversion was assessed for first- and second-order single phase reactions at different Damköhler numbers using the segregation and maximum mixedness micromixing models combined with the fitted RTDs. The performance of the coil remained consistent with a plug flow reactor despite its departures from ideal flow.