The performance of multiphase flow processes is often determined by the distribution of phases inside the equipment. However, controllers in the field are typically implemented based on flow variables, which are simpler to measure, but indirectly connected to performance (e.g., pressure). Tomography has been used in the study of the distribution of phases of multiphase flows for decades, but only recently, the temporal resolution of the technique was sufficient for real-time reconstructions of the flow. Due to the strong connection between the performance and distribution of phases, it is expected that the introduction of tomography to the real-time control of multiphase flows will lead to substantial improvements in the system performance in relation to the current controllers in the field. This paper uses a gas–liquid inline swirl separator to analyze the possibilities and limitations of tomography-based real-time control of multiphase flow processes. Experiments were performed in the separator using a wire-mesh sensor (WMS) and a high-speed camera to show that multiphase flows have two components in their dynamics: one intrinsic to its nonlinear physics, occurring independent of external process disturbances, and one due to process disturbances (e.g., changes in the flow rates of the installation). Moreover, it is shown that the intrinsic dynamics propagate from upstream to inside the separator and can be used in predictive and feedforward control strategies. In addition to the WMS experiments, a proportional–integral feedback controller based on electrical resistance tomography (ERT) was implemented in the separator, with successful results in relation to the control of the distribution of phases and impact on the performance of the process: the capture of gas was increased from 76% to 93% of the total gas with the tomography-based controller. The results obtained with the inline swirl separator are extended in the perspective of the tomography-based control of quasi-1D multiphase flows.

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This text structures the application of Wire-Mesh sensors and Electrical Resistance Tomography in the control of an Inline Swirl Separator. It introduces a mechanistic model of the two-phase flow inside the device, which is linearized around an ideal perfect operation, and implemented in a Model Predictive Controller. The whole text is structured aiming at a future real application of the controller, briefly introducing the setup that is going to be used, the sensors and their working principles. The results obtained show a stable controller, able to regulate the process relatively fast in relation to the time resolution of the sensors. The positive response of the approach stimulates further improvements in the model developed, and the implementation of more sophisticated techniques to handle the non-linearities of the process.

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The influence of dense vertical tube bundles in a batch bubble column reactor (BCR) of 100 mm diameter and 1100 mm clear liquid height on liquid dispersion and gas-liquid mass transfer was studied. In particular, the effects of different tube patterns (triangular and square pitch), tube diameters (8 and 13 mm) and bottom end designs (flat and U-tube) having a tube diameter-to-pitch ratio of approx. 1.3 were investigated. Dispersion coefficients were determined based on conductive tracer experiments recorded via wire-mesh sensors (WMS) with up to 90 measurement points distributed in the column's cross-section in between the tubes. The gas-liquid mass transfer coefficient was determined via fast-responding oxygen needle probes. Tube pitch and pattern were identified as the most crucial design parameters for the extent of liquid dispersion. We found that particularly the U-tube bottom end design induces large liquid circulation patterns, which enhance dispersion. The presence of internals decreases the kla value as a consequence of turbulence damping, which is also confirmed by lower kl values (e.g. 0.6 × 10−3 m s−1 for the empty BCR and 0.25 × 10−3 m s−1 for the square pitch with 8 mm tubes at 0.05 m s−1 superficial gas velocity), whereas the pitch is the most decisive design parameter. The U-tube bottom end design was identified as the most beneficial configuration with respect to liquid mixing and gas-liquid mass transfer.@en