' .

Explore the Potential

of Air-Lift Pumps
and Multiphase

This is in accord with analogous experi

(5). recycle aeration in sludge digestors

(6), deep sea mining (7), and the recovery
of manganese nodules (8,9,10) from

some amount of scatter in published

pplications of so-called "air-lift

pumps" in fields other than
petroleum (I) have included
the handling of hazardous flu
ids (2), the design of bioreactors (3,4),
the recovery of archeological artifacts

Use this
new capacity
correlation for
pump design.

f. A.Zenz.
AIMS

experimental data on air-lift capacity.

Since injected gas bubbles are dis
placed upwardly by the downward "slip"
flow of liquid (that is, dense phase (23))
at the walls, the cross section through an
upward moving gas bubble represents a
countercurrent flow as depicted in Figure
le despite a net upward transport of slugs
of liquid. This local countercurrent flow

design and operation of an air-lift pump

is analogous to the empty pipe flooding

The transition to slug flow

The entrainment of spray or droplets
as occurs from a fractionator tray consti

, ..::

ence in the injection of flashing feeds into

risers in fluid catalytic cracking units,
an alo gously carrying upwardly bulk
solids (particles) as opposed to bulk liq
uids (molecules), and also accounts for

ocean floors. Interest among a host of

domestic (//-17,18) and foreign (/9)
organizations dates back several decades;
having passed EPA hurdles (20), recovery
of ocean resources has been further sanc
tioned by U.S. legislation (/7). With the
exception of "bioreactors" the practical
lies in the dense-phase slug-flow regime
of cocurrent gas-liquid upflow (21).

t'.'

phenomena illustrated in Figure Id for

which correlations already exist (24). In
view of the identical flow phenomena in
Figures le and Id, accounting for the sys
tem variables should also be identical
whether the net flows are cocurrent or
countercurrent

tutes a form of dilute phase cocurrent

gas-liquid upflow. Since bubble caps
have been used as foot pieces in gas lift
pumps, a pipe set over a cap on a tray, as
illustrated in Figure 1 a, constitutes con
c e p t u a lly a low efficiency bubbling
upflow gas lift operating at very shallow
submergence. In practice, a gas lift oper
ates with deeper submergence, and more
efficiently in slug flow, as depicted in

Dense phase liquid

transport by gas-lift pumps
In Figure I b, gas compressed to a
pressure level equivalent to the depth of
submergence is introduced to the lift pipe
to displace liquid upwardly. As the liquid
flows back down into the bubble-form

Figure I b where the foot piece is simply

voids, more gas is continually introduced

to establish a steady state of refluxing of

a gas injection nozzle.

In practice, multiport injectors have
been found to be more efficient (22) in
terms of increased capacity, particularly
in the bubbling and slug-flow regimes.

upwardly displaced liquid. The net rate of

conveyance or refluxing decreases with
height of lift. If the pipe is cut off at some
height, below the maximum commensu
rate with the given gas rate, or of the dif-

CHEMICAL ENGINEERING PROGRESS

AUGUST 1993

51

FLUIDS/SOLIDS HANDLING........,

(bl

fa)

'

;'

-.,.o
.

>

104

Vo
t ri-VL

11)3

:''

A= Pii>u crossseelion, sq. h.

D PiJ!e Ld inches
l .. Lilt. h.
S .. Submerguncu, h.
p6 Gas density
PL = Fluid density

_
.
.

,-''

'1:}

' ' -

'

.... :

"

. " f

101

101
' .

. .

'

.
, ,

\ , :,_'

f: .'t,
Vo'

11J3

"

..

l>j.-<

VL."

..

.'

'.

--.:....

Figure 1. (above) Dilute-dense phase manifestations.

10

. ,

...

10

100

1000

10

Figure 2. (right) "Con-elation" ofair-waler lift data.

ference in hydraulic head, then the
net rate of liquid at that height will
be continuously expelled from the
pipe and hence the action referred to
as a lift "pump."

Experimental air-lift data

Figure 2 displays a variety of pub
Ii shed a i r-lift data c overing lift
heights ranging from 5 in. to 65 ft
and pipe diameters from in. to 15
in. The curves drawn through each
investi gator's results f all into a
numerical sequence with height of
lift. The basis for the choice of coor
dinates in Figure 2 lays principally in
their ability to correlate maximum
countercurrent dilute phase-dense
phase flow through empty vertical
tubes and packed towers (23,24).
T hat these coordinates yield a plot as
organized in Figure 2 lends credibili
ty to this approach to correlation,

52

AUGUST 1993

despite the fact that air lift represent

overall a net cocurrent , rather than
countercurrent, flow.
In Figure 2 gas volume and gas
density are based on discharge con
ditions; within a long lift pipe these
could vary significantly from inlet to
discharge. However, the significance
of "corrections" to the data in Figure
2 would be difficult to evaluate justi
fiably when even the best data are
subject to experimental error and to
the effects of the air injection arrang
ments (22).
The submergence term, S, in the
denomin at or of the ordinate of
Figure 2 is based on analogy to cor
relating data on entrainment from
distillation trays (25). It also reflects
the work expanded in compressing
the air in an air lift. If S is replaced
by log [(S + 34)/34 ] which is pro
portional to the work of compression
and still reflects the submergence,

CHEMICAL ENGINEERING PROGRESS

then the data in Figure 2 yield a fam

ily of parallel curves spaced accord
ing to the square root of the lift
height. Multiplying the ordinate and
dividing the abscissa by the square
root of L results in the correlation of
Figure 2.

Effect of fluid density

Since all the data in Figure 2 are
based on lifting water, the question
arises as to how well this correlation
would satisfy other fluids. The ordi
nate should be modified by consid
ering that increased liquid density
would logically result in reducing
the effective volumetric yield, or
conversely giving the same wieght
yield at equal air rates. Chamberlain
(2) obtained air-lift data for both
water and a 93.5 lb/ft3 caustic solu
tion in the same pipe; his data are
plotted in Figure 3 and show excel-

lent correlation. Figure 3, which rep

resents a smoothed ban d drawn
through the data in Figure 2 may
therefore be considered a more gen
eralized correlation.

Abscissa

ofFigure4

W0= W,.L

(1)

W1 =Pa VG In (PIP)

(2)

The work (isothermal compression)

expended by the dilute phase (air) in
lifting the liquid is:

and the fractional efficiency,

therefore:

E= WJW1

E,

is

(4)
E= W,. UPa VG In (PIP0)
(See Equations A, 5 and 6.) The pub

lished version of the Ingersoll-Rand

equations is simply Eq. 6 with the
term (469 E) replaced by a constant
which in effect amounts to assigning
a value to E. Operationaily deter
mined values of E are generally of
the order of 40 to 50% at the point of
maximum operating efficiency, as
given in Table 1 (26).
From the Ingersoll-Rand equation

62.4

3.14(6)2

\f;

48
6

1
x- =O 0916

30

'G

'- 144x14 .7 Exln [(34+S)/34]

Equat ions

(SCFM)Air

(GPM)Water -

0.8 L
469 Exlog [ (34+S)/34]

Equalion 6

(SCFM/fr2)(48/D)112
(GPMJJt2)( 48/D)112

0.8 L
Cxlog [(34+S)/34]

Equation 7

(VdA)(48/D)112 (pdp!)1121L112

------ =

(\f.IA)(48/D)1f2 L lf2/log ([ S +34}':34]

0.8 (pdpJ
c

Equalion8
alone, it is impossible to predict the
variation in a given lift pipe's per
formance as air rates are changed.
The equation gives the air-to-water
ratio only at the point of peak effi
ciency and would imply that this
ratio is constant at all air rates. It is
evident from Figures 2 and 3 that the
water rate falls off sharply when the
air rate is either less (in the bubbling

(3 )

Since Pa= 34 ft of water or 14.7 psia,

P may be expressed as 34 + S, where
S is the submergence in ft, so that

0.0765

EquationA

The Ingersoll-Rand equation

The theoretical efficiency of an
air lift is simply the work required
to lift the liquid to the point of dis
c h arge divided b y t h e work of
isothermal compression of the air.
When analyzed in these terms, the
air-to-liquid ratio can be expressed
as a function of lift height, submer
gence, and efficiency. This relation
ship is generally recognized as the
Ingersoll-Rand equation (26,27)
and is usually accompanied with
t a b ul ated v al ues o f a constant
derived from experimental data at
or near the point of maximum effi
ciency of operation as a function of
the lift height.
The work required to lift the
dense phase (liquid) to the point of
discharge is:

\.6X4 X 144

flow regime) or greater (in the annu

lar or mist flow regime), than near
the point of optimum slug-flow
operation (28).
Multiplying numerators and
denominators by equal terms, the
Ingersoll-Rand equation can be
rearranged for graphical comparison
with Figures 2 and 3. From Eq. 6 see
Eq.7 or Eq. 8 . For standard air and

106
Data of Chamberlain
[) = 1.6"
L= 10ft.
Band of data
- in figure 3.
S = 10ft. at PL= 62.4
Self= 1 Sft. at PL = 93.5

1 .____;_..;,_
1

Figure
3.Effecto/
fluid
density.

'
. .

___J
_
L-________..._______

____

to

100

1,000

Vo
A VDLPL
CHEMICAL ENGINEERING PROGRESS AUGUST 1993

53

FLUI OS/SOLIDS HANDLING "'-"

'r\\,:;.\
----------

;.:.:;.;.:;.:.;.;.;.;;-.-

1oe-------,-----.

.:

-......

'. 10Wgt % Sand

Ingersoll-Rand
equation -,..___,.,...,,
E=50%

:: .

soWgt

Fluid
% Water Rate

PG=0.0765

Air
Rate

Air
Rate

Pr= 62.4

101"'========='====
'

100

10

j4iP;
v 0LPr

VG
A

1,000

Figure 4. Significance ofthe Ingersoll

Rand equation.

Nomenclature

now, sq. ft.

pipe cross-sectional

pipe inside diameter, in.

pressure at point of gas entry.

VG
VL
w,

fractional efficiency, WJW1

lift height, ft.

lb/sq. ft.

P.

area. sq. ft.

atmospheric pressure, lb/sq. ft.

=

submergence, ft.

gas now at discharge conditions,

ft'lmin

dense phase now. gal/min

pounds of dense ph11SC lifted per
minute

w,

w..

worlc input ft-lb/min

=

work output ft.lb/min

Greek Letters

gas void fraction in aerated

dense phase

P1
Po
Pt

54

water (that is, PL =

0.0765), Eq. 8 is then

0.028

cross-sectionul area of annular

Figure S. A ir-lift examples.

viscosity of lifted fluid.

entipoise

surface tension of lifted fluid,

dynes/cm
density of lifted fluid, lb/ft'
gas density. lb/ft'
liquid density. lb/ft'

AUGUST 1993

62.4; Pa
(9)

10&
=

..----

105

1-Bubbling

Equation 9 is shown in
F i g u r e 4 as s up e r i m2
'" ? ,
I;
,,
c:::n
posed on Figure 3. The
lt.-A
1 ..
..5!
Cl ..
Ingersoll-Rand equation
-:
t?
Slugging
plots as a straight line
-/
I LA...

::I.
104

with slope correspondco

...
d:
Ill
ing to the ai r-to-water
::I
c
b
N
'
ratio at peak theoretical
,...
I
efficiency. T h e c u r v e
rT
I
.
b ased on experimental
103
data exhibits this same
>'I<
slope at only one point,
Mist
but then curves away to
yield lower water-to-air
ratios at values of the abscissa
(air rate ) higher or lower than 102
1
10
100
1,000
that corresponding to the ratio at
this point of maximum delivery
efficiency. The Ingersoll-Rand
A
equation is therefore useful in
Figure 6. Multiphase cocurrent
estimating the yield from an air
vertical upjlow regimes.
lift only under conditions of peak
Examples
theoretical effici ency, b u t n o t
Consider the operable gas-liquid
over the entire range of possible
operating conditions . Figures 3
solids ratios for two situations illus
trated in Figure 5:
a n d 4 i n c o r p o r a t e as w e l l the
effect of fluids of densities other
1. Air l ifting of water 30 ft
than water.
through a 6 in. pipe submerged 50 ft.

I,
L

.i

Vo

v OLP;'

CHEMICAL ENGINEERING PROGRESS

----------- -

____________

;'.

'

Ordinate
o/Figure4

EquationB

Abscissa
ofFigure4
Equation C

\fX4 x144
3.14(6>2

'6x4 x144
3.14(6)2

Ordinate =(SlurryGPM)x4x 144

ofFigure4
3.14(6)2

/f

0.0765

48

66.5

{48
V 6

66.5
62.4

112
(30)
/og{(34+50}'34]

-133.1

=201 v,

'L

= 0.0844 (ACFM)

(33.1)112
log{(34+ 46.9}'34]

=235(SlurryGPM)

Equation D
2. Air lifting of a sedimented
sand, as a slurry containing 10 wt.%
fine sand, a distance of 30 ft through
a 6 in. pipe submerged 50 ft.

Case/.

See Eqs. A, B and Table 2.

Case 2.
Slurry density= l/((0.1/165)

+ (0.9/62.4))

= 66.5 lb/ft3
Effective submergence=
50 (62.4/66.5)= 46.9 ft.
Effective Lift = 30 + 50- 46.9= 33.1 ft.
See Eqs. C, D and Table 3.

Bubbling and annular

liquid flow
At values of the abscissa less than
about 50 and to the left of the curve
in Figure 4, two-phase flow would
occur in the form of gas bubbles ris
ing in a matrix of liquid forced to
flow upwardly by means, for exam
ple, of a motor driven pump or sim
ply by a hydraulic difference in head.
Under such conditions, typical in
bioreactors (3), L would be the tube
diameter and S would equal

Lp/ (1 - e}.162.4

At values of the abscissa greater

than about 50, and to the right of the
curve in Figure 4, voidage must be
so great that liquid can only be dri
ven up the pipe in annular flow by
the surface drag of the gas core. This
region has been explored in some
detail by Dukler and others (29.30)

CHEMICAL ENGINEERING PROGRESS

AUGUST 1993

55

FLUIDS/SOLIDS HANDLING

Acknowledgment

r-..:_

-: :,.'.,:-.-

.
-: :/'i.

Literature Cited

;'.;c-Ontract with Union C a rbide Corporation

';1ir3trUlly acknowledged.
;./:_..--:' .

ls:

))'
... :}.
.

Mining Research

>\.:tt(
iJ.=J.A.:ZENZ is president and technical dircw:'ft

;1t :;:._ : ' \ . :

Bureau of Mines,

._.

m:](''\'

\vt

:.

AUGUST 1993

CHEMICAL ENGINEERING PROGRESS

88(10), pp. 93-98'(('

24. Zenz, F. A., and .

Hydocarbon Proc .

pp. 121-126 (1965):{

25. Schweitzer, P. A;,

Separation Techni '
Chemical

En8ii1

Hill, New Yorkpp

who presented experimental data relating

measured amounts of liquid, carried upward
i n annular films of measured thickness
inside a vertical 2 in. internal diameter (ID)
pipe, to the measured rate of the cocurrent,
liquid flow inducing, upward gas stream.
The results are shown in Figure 6 with
the ratio of film cross-sectional area to pipe
cross-sectional area as a parameter.
Equating bubble rise velocity to displacing
liquid downflow in a slugging tube, corre
sponds to an annulus-to-tube area ratio of
0.385, suggesting that these investigators
were approaching slugging and that this
limit should at some time be established on
Figure 6 experimentally. The addition of
liquid viscosity and particularly surface ten
sion terms to the ordinate of Figure 6 has
been, somewhat arbitrarily, based on identi
cal terms applicable to horizontal multi
phase flow (31) and on data obtained for
very low surface tension liquids in cocur
rent upflow with air (32) in tubes several in.
to several ft in diameter.
Fi g u r e 6 r e p r e s e n ts n o t o n l y a
capacity correlation for gas lift pump
design, but also suggests the correla
tion of all regimes of cocurrent multi-

56

Equation," Chent. -

p.
Engi11iT,tJ8!Jl:
ptPJt
mot[' -,,. .
'
' :::h?--

ljfrm

.
Tit(.

(May 1965).
J
22. Morrison, G. L., et
Res., 26, 387-391 (19 "
23. York, J, L., et al., ;'
Column Flows Waill

'JMS,.Garrison, NY (914/4243220; Fax: 914/414.

' )_a non profit industrial consortiu
' . ed his PhD in chemical engineering ..
echnic University, New York;'; ;. 'l
1!$0r Emeritus at Manhattan JJ,ifllfii.'.
ow"of the AIChE, the 1985 recipianf
i>t
d in chemical engineering
).$86 recipient of Chemical
-. anal Achievement Award. In the
. .he has authored 90 papers, 2bookS, 19 USit
:l
: : '.nd has been 8 consultant to
J and domestic corporations. .\'.f'J,
fciriiign

.. ,.

. \
33-J4',;-::;;'

19. Chem. Week, pp.

:-;:\;,(July 30, 1980).
20. Chem. Eng p. 20 (No'
1980 ).
:-
21. Padan, J, W., "The' .,,

ldr. Sylvan Cromer's kind permission to publiSh/

td.io_se portions of this article developed under 'a>

(1988).
<
26. "Chemical Etl:'
Handbook," 4th
Hill

pp. 6-13; Cf,.

IngersollRand

.ll!J!i
'.

(July 1929) ,7,'.

27.Duckworth, C.
p. 63(March1960}
28. Nemet, A.G., JmJ.o
53(2), pp. 1SHS4,'
29. Zab
G et- .,
.

.. ,,,.,.
Cocurm..i
t ..

aras,
Upward

. .

Annular Flow,'' Ai

PP

829-843 098ii
'

30. Taltel, Y. et ."

Patterns

Upward

Transit!,.

Gas-Uqui4.F.'!J

Vertical Tubes,':'Al

pp.

345.354 (1980).::t..,

31. Baker,o.,0;1'&diii ,: '"

195, 53(12)(July 26$f

32. Zenz, J. A., pm01ilif

cation, PEMM
NY (1986).

phase upflow to the extent supported

by data published to date .
Di1
To receive a free copy of this article, sand
in the Reader Inquiry card in this Issue
with the No. 136 circled.

Cori{..
: :i:

'

:-.. --